Patent Abstract:
A flat belt support system with a drive roller and paired pulleys, each pair carrying a continuous flat belt that can be moved laterally along the drive roller axis and angled away from the plane normal to the drive roller axis. Multiple belts, each carried by a pair of pulleys, can be driven by a single drive roller. An additional roller allows the drive roller to be positioned so that it contacts the flat belt cover, rather than the back of the flat belt, improving friction between the drive roller and the flat belt.

Full Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates to a flat belt support system configured with an arrangement of a supporting roller, pulleys and a continuous flat belt such that flat belt may be driven by a driving roller and a belt path is created and controlled by articulating the support pulleys relative to the driving roller such that the flat belt will naturally tend to stay roughly centered on the pulleys while traveling about the belt path created. A variety of configurations using these components are common practice in many applications where the centerline of the belt path is essentially coplanar in a plane which is normal to the axis of the driving roller. However, this invention allows the pulleys to be articulated relative to the roller such that the centerline of the belt path is no longer coplanar. This invention allows objects conveyed by the flat belt to be selectively diverted from the plane normal to the axis of the driving roller. This invention also allows the belt path to move laterally along the axis of the driving roller. 
         [0002]    This invention creates an advantage in applications in which it is desirable to have a single or plurality of flat belts being driven by a single driving roller while also needing to articulate each belt path independently to each other by adjusting both the relative spacing between the belts and the skew of the belts from the plane normal to the axis of the drive roller. 
         [0003]    There are two very common industrial uses for flat belts as shown on  FIG. 5 . The first is the transmission of power from one driving rotary shaft to another driven rotary shaft via the use of pulleys and one or more flat belts. The second is for the purpose of conveyance in which one or more flat belts are driven with the intention of transporting another material or objects along the conveyance surface of the flat belting. 
         [0004]    This invention is related to a need for conveyance of objects. It can be used in any industry where there is a need to convey objects in a flow direction with the added requirement of needing to laterally shift the conveyed objects relative to a straight flow direction and/or relative to the other objects being conveyed. 
         [0005]    While it can be used in a variety of industrial applications, one common application is in the material handling of cardboard/corrugated sheets. In particular, during the production of corrugated flat boxes by a machine known as a Rotary Die Cutter, corrugated flat boxes are produced by converting a large rectangular feed sheet into multiple smaller flat boxes using a die cutting processes. The die boards are attached to a rotating drum and the material is fed through with the die board cutting the large rectangular sheet in both the material flow direction and perpendicular to the material flow direction to produce the multiple smaller flat boxes. These flat boxes qualify as objects which may be conveyed by the conveyance surface. 
         [0006]    The term “UPS” is used throughout this patent in reference to the number of flat boxes produced due to cutting in the perpendicular to the material flow direction where as the term “OUTS” will be used in reference to the boxes produced due to cutting in the direction parallel to the material flow direction. 
         [0007]    For many years there has been the need to collect these multiple UPS and OUTS of smaller flat boxes as they exit the Rotary Die Cutter and place the boxes into stacks of boxes for further processing downstream. There have been a multitude of stacking machines that have been produced to service this need. One form of sheet stacker is found in U.S. Pat. No. 2,901,250 granted to Martin on Aug. 25, 1959. A second form of sheet stacker is found in U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991. 
         [0008]    One of the challenges of stacking the flat boxes is that during the process of making the stacks of boxes, it is often desired to separate the OUTS laterally as they are conveyed away from the Rotary Die Cutter. This lateral separation keeps the individual flat boxes from becoming interleaved with each other during transport and also allows for dividers to be placed between the individual stacks being produced to improve the integrity of the stacks of boxes. In  FIG. 7B , a set of grooved belts referred to as Layboy Arms  53  are arranged in order to create the lateral separation. This need has also been addressed in the following patents: U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975, U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991, U.S. Pat. No. 6,000,531 granted to Martin on Dec. 14, 1999, and U.S. Pat. No. 6,427,097 granted to Martin on Jul. 30, 2002. 
         [0009]    The usage of round, V-grooved and other grooved type belt conveying means affords the option of creating the laterally skewed belt path in a multiple number of ways since they each can be controlled by the position of the entrance and exit pulleys. These pulleys do not even have to stay in the same plane as the plane defined generally by the centerline of the belt path since the belts are forced to track each pulley with some method of grooving or rim on the pulleys. One form of this method in shown in U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975 
         [0010]    Because of the total width of large industrial machinery including the sheet stackers, it is desirable to be able to skew larger width flat belts which rely on the tracking of their belts back surface as opposed to providing the large number of narrow grooved belts which would be required to support both large and small boxes across the entire width of the sheet stacker. 
         [0011]    The prior art includes systems that allow the diversion of flat belts but do so by keeping the entrance velocity plane and exit velocity plane essentially coplanar or parallel, unlike the current invention which allows the exit velocity plane to be both non-coplanar and non-parallel. 
         [0012]    U.S. Pat. No. 2,901,250 granted to Martin on Aug. 25, 1959, U.S. Pat. No. 3,860,232 granted to Martin on Jan. 14, 1975, U.S. Pat. No. 5,026,249 granted to TEI on Jun. 25, 1991, U.S. Pat. No. 6,000,531 granted to Martin on Dec. 14, 1999, and U.S. Pat. No. 6,427,097 granted to Martin on Jul. 30, 2002 are hereby incorporated by reference. 
       SUMMARY OF THE INVENTION 
       [0013]    The Diverting Flat Belt Support System of the present invention is a support system configured from rollers and pulleys that create a belt path for a continuous flat belt which can be used for the conveyance of objects. The flat belt conveyance surface has an entrance portion, entrance velocity point, entrance velocity plane, entrance velocity vector and entrance axis of rotation. The conveyance surface has an exit portion, exit velocity point, exit velocity plane, exit velocity vector and entrance axis of rotation. While not required, entrance velocity point and exit velocity point are typically the beginning and end of the entrance portion and exit portion respectively. While not a requirement of the invention, a static conveyance surface support member may be provided to increase conveying capacity. The entrance velocity plane and the exit velocity plane may selectively be changed between coplanar and variable degrees of non-coplanar and non-parallel by articulating the supporting pulleys relative to the rollers. 
         [0014]    Another objective of this invention is to allow the flat belt to track the support system properly even when the entrance velocity plane and exit velocity plane are non-coplanar and non-parallel. 
         [0015]    Another objective of this invention is to produce a belt path that curves along the conveyance surface such that the objects being conveyed will be gradually shifted laterally. 
         [0016]    A further objective of this invention is to allow the entrance velocity plane to be shifted laterally along the associated axis of rotation in order to allow variable spacing when a plurality of flat belts share a common roller. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1A  is a side view of a generic pulley and belt path used to define the terms related to a flat belt and grooved belts. 
           [0018]      FIG. 1B  is a cross-sectional view of a generic flat belt and pulley. 
           [0019]      FIG. 1C  is a cross-sectional view of a generic irregular flat belt and pulley. 
           [0020]      FIG. 1D  is a cross-sectional view of a generic V-grooved belt and pulley. 
           [0021]      FIG. 1E  is a cross-sectional view of a generic round belt and pulley. 
           [0022]      FIG. 2A  is a perspective view used to define the terms related to a roller. 
           [0023]      FIG. 2B  is a cross-sectional view used to define the terms related to average contact centerline belt path. 
           [0024]      FIG. 3A  is a perspective view used to define the terms related to a pulley, both crowned pulleys and flat pulleys. 
           [0025]      FIG. 3B  is a right side elevation view of  FIG. 3A  used to define the terms related to a pulley, both crowned pulleys and flat pulleys. 
           [0026]      FIG. 3C  is a cross-sectional view of  FIG. 3B  used to define the terms related to a crowned pulley. 
           [0027]    FIG.  3 C′ is a cross-sectional detailed view of  FIG. 3C  used to define the terms related to a crowned pulley. 
           [0028]      FIG. 3D  is a cross-sectional view of  FIG. 3B  used to define the terms related to a flat pulley. 
           [0029]    FIG.  3 D′ is a cross-sectional detailed view of  FIG. 3D  used to define the terms related to a flat pulley. 
           [0030]      FIG. 4A  is a perspective view used to define the terms related to a flat belt tracking. 
           [0031]      FIG. 4B  is a right side elevation view of  FIG. 4A  used to define the terms related to a flat belt tracking. 
           [0032]      FIG. 4C  is a cross-sectional view of  FIG. 4B  used to define the terms related to a flat belt tracking. 
           [0033]      FIG. 4D  is a cross-sectional view of  FIG. 4B  used to define the terms related to a flat belt tracking. 
           [0034]      FIG. 5A  is a perspective view used to define conveyance usage of flat belts. 
           [0035]      FIG. 5B  is a perspective view used to define power transmission usage of flat belts. 
           [0036]      FIG. 6A  is a top plan view of Rotary Die Cutter used to define the terms related to the production of flat boxes with a Rotary Die Cutter. 
           [0037]      FIG. 6B  is a perspective view of Rotary Die Cutter cylinders used to define the terms related to the production of flat boxes with a Rotary Die Cutter. 
           [0038]      FIG. 7A  is a side elevation view of a sheet stacker used to describe why the lateral shifting is required during the making of stacks of boxes. 
           [0039]      FIG. 7B  is a top plan view of a sheet stacker used to describe why the lateral shifting is required during the making of stacks of boxes. 
           [0040]      FIG. 8A  is a side elevation view which illustrates the basic elements of the flat belt and most basic support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity. 
           [0041]      FIG. 8B  is a perspective view which illustrates the basic elements of the flat belt and most basic support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity. 
           [0042]      FIG. 8C  is a perspective view which enlarges details of  FIG. 8B  and illustrates the exit elements of the flat belt and most basic support system in side view and isometric view. 
           [0043]      FIG. 8D  is a perspective view which enlarges details of  FIG. 8B  and illustrates the entrance elements of the flat belt and most basic support system in side view and isometric view. 
           [0044]      FIG. 9A  is a side elevation view which illustrates the basic elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity. 
           [0045]      FIG. 9B  is a perspective view which illustrates the basic elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. The articulating system constraining these elements has been removed for clarity. 
           [0046]      FIG. 9C  is a perspective view which enlarges details of  FIG. 9B  and illustrates the entrance elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. 
           [0047]      FIG. 9D  is a perspective view which enlarges details of  FIG. 9B  and illustrates the exit elements of the flat belt and the preferred embodiment of the support system in side view and isometric view. 
           [0048]      FIG. 10A  is a top plan view which illustrates the conveyance surface when the entrance velocity plane and the exit velocity plane are coplanar. 
           [0049]      FIG. 10B  is a top plan view which illustrates the conveyance surface when the entrance velocity plane and the exit velocity plane are not coplanar and not parallel 
           [0050]      FIG. 11  is a side elevation view which illustrates the tangent surface vectors of this invention. 
           [0051]      FIG. 12A  is a perspective view which illustrates a parallel roller and terms related to the explanation of flat belt tracking tendencies. 
           [0052]      FIG. 12B  is a top Plan view of  FIG. 12A  which illustrates a parallel roller and terms related to the explanation of flat belt tracking tendencies. 
           [0053]      FIG. 12C  is a perspective view which illustrates a taper roller and terms related to the explanation of flat belt tracking tendencies. 
           [0054]      FIG. 12D  is a top plan view of  FIG. 12C  which illustrates a taper roller and terms related to the explanation of flat belt tracking tendencies. 
           [0055]      FIG. 12E  is a perspective view of crowned pulley and flat belt used to define the terms related to the explanation of flat belt tracking tendencies. 
           [0056]      FIG. 12F  is a cross section view of  FIG. 12E  used to define the terms related to the explanation of flat belt tracking tendencies. 
           [0057]    FIG.  12 F′ is a cross section view detail of  FIG. 12F  showing belt with theoretical gap. 
           [0058]    FIG.  12 F″ is a cross section view detail of  FIG. 12F  showing belt conforming to pulley. 
           [0059]      FIG. 13A  is a perspective view of torque source for rollers 
           [0060]      FIG. 13B  is a perspective view which illustrates the basics of an articulation system. 
           [0061]      FIG. 14A  is a perspective view which illustrates the basic elements of a plurality of flat belts and a plurality of the most basic support system. 
           [0062]      FIG. 14B  is a side elevation view which illustrates the basic elements of a plurality of flat belts and a plurality of the most basic support system. 
           [0063]      FIG. 15A  is a perspective view which illustrates the basic elements of a plurality of flat belts and a plurality of the preferred embodiment support system. 
           [0064]      FIG. 15B  is a top plan view which illustrates the basic elements of a plurality of flat belts and a plurality of the preferred embodiment support system 
           [0065]      FIG. 16  is a perspective view which illustrates a complete sheet stacker machine with the integration of a plurality of flat belts and a plurality of the preferred embodiment support system. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0066]    The following terms are defined to provide clarity throughout this patent. 
         [0067]    The term flat belt  4  is used throughout this patent to refer to the type of belt that has its tracking controlled by the belt&#39;s back surface  7  and the support system  84 . This is unlike a class of belts which may be referred to as grooved belts  5 ,  6  shown in  FIG. 1  illustrated in a generic configuration  1  with two generic pulleys  2 ,  3 . The tracking of grooved belts  5 ,  6  is controlled by the belts being constrained by contact force with the sides  9 ,  9 ′ of the belt. This is typically achieved with grooves in the pulleys  8 ′,  8 ″ and typical examples include V-Grooved Belting  5  and Round-Grooved Belting  6 . Thus, while the term flat belt  4  may describe a belt with a parallel cover  10  and back surface  7 , it would also include any belt  13  with a non-flat back surface  11  and/or a non-flat cover  12  as one example provided the tracking is still controlled by the belt&#39;s back surface  11 . 
         [0068]    The term centerline belt path  83  is used throughout this patent and is defined in  FIG. 1A-1E  as the continuous path created by the belt&#39;s center of cross sectional area axis. 
         [0069]    The term average contact centerline belt path  93  is used throughout this patent and is defined in  FIG. 2B  as the average lateral position of the centerline belt path  83  along the rotational axis  17  where the back  7  of the flat belt  4  is in contact with the surface  8 . 
         [0070]    The term support system  84 ,  84 ′ is used throughout this patent and is defined shown  FIG. 8A-8D  and  FIG. 9A-9D  as only those elements that directly affect the belt path  83  of the flat belt  4 . 
         [0071]    The term articulation system  85  is used throughout this patent and is defined in  FIG. 13  as the elements that interconnect the elements of the support system  84 ,  84 ′ and allow the desired movement of the support system  84 ,  84 ′. 
         [0072]    The term roller  14  is used throughout this patent and is defined in  FIG. 2A  as a parallel cylindrical object with a center rotational axis  15  and is substantially wider than the flat belt  4  which may allow for a plurality of flat belts  4 ′,  4 ″, . . . to be in contact directly with the surface  16  of the roller  14 . In the preferred embodiment a roller  14  would have parallel surfaces  16  but this is not always required. 
         [0073]    The term conveyance surface  30  is used throughout this patent and is defined in  FIG. 2A  as the cover  10  side of the flat belt  4  upon which objects may be conveyed by the motion flat belt  4  along the flat belt path  83 . 
         [0074]    The term velocity point  31  is used throughout this patent and is defined in  FIG. 2A  as the point on the centerline belt path  83  where the conveyance surface  30  begins or ends contact with a roller or pulley. 
         [0075]    The term velocity plane  28  is used throughout this patent and is defined in  FIG. 2A-2B  as a plane perpendicular to a central rotational axis  15 ,  17  which intersects the average contact centerline belt path  93 . 
         [0076]    The term velocity vector  29  is used throughout this patent and is defined in  FIG. 2A  as a vector beginning at the velocity point  31 . The magnitude of the velocity vector  29  is based on the angular velocity and geometry of the associated roller or pulley as well as the geometry of the flat belt  4 . The direction of the velocity vector is along the intersection of flat belt cover  10  and the velocity plane  28 . 
         [0077]    The term pulley  8  is used throughout this patent and is defined in  FIG. 3A-3D  as generally cylindrical shape object with a center rotation axis  17  and is similar in width to the flat belt  4  and is in contact with a single flat belt  4 . If the outer diameter of the pulley  18 ″ is essentially the same across the length of the pulley, it will be referred to as a “flat pulley”  25 . If the outer diameter of the pulley  18 ′ is variable across the length of the cylinder such that the outside diameter in the center of the cylinder  19  is larger than the outside diameter at the ends of the cylinder  19 ′, it will be referred to as a “crowned pulley”  24 . 
         [0078]    The term “tracking” is used throughout this patent and is defined in  FIG. 4A-4D  as maintaining the lateral position  20  of the center plane  22  of the flat belt  4  where it contacts a pulley  24 ,  25  relative to center plane  21  of the pulley  24 ,  25  such that there is little or no offset  23 . That is, a flat belt properly “tracking” a pulley  24  will stay on the pulley near the center of the pulley where as a flat belt that is not “tracking” a pulley  25  will run off center of the pulley or completely fall off the edge of the pulley. Note that while crowned pulleys  24  do tend to track better than flat pulleys  25  there are many other support variations that effect tracking and  FIG. 4  is illustrated as an example of tracking only. 
         [0079]    Flat belts  4  have been used for many years in industrial applications. This invention relates to a flat belt  4  in the application of conveyance  33 . A flat belt  4  is often connected to itself to form a continuous flat belt. Since the belting material is flexible it requires a support system  84  to constrain the flat belt  4  to follow a desired belt path  83 . The support system  84  is typically created from rollers  14  and pulleys  8 . Optionally, additional other static support structures  64  may be included upon which the back  7  and/or cover  10  of the flat belt  4  may slide for extra support to avoid sagging due to gravity and/or to support objects  38  being conveyed. Since the support system  84  is only those elements that directly affect the belt path  83  of the flat belt  4 , an additional articulation system  85  is required in order to interconnect the elements of the support system  84  and allow the desired movement of the support system  84 . The configuration of the support system  84  and defining the appropriate articulation constraints of the support system  84  is the primary focus of the invention. The articulation system  85 , while being required and described herein, can be accomplished in a multitude of similar ways by those skilled in the art. 
         [0080]    For the purpose of this patent, a flat belt  4  is defined as the type of belt having a back  7 , an outer cover  10  and a centerline belt path  83  that has its tracking controlled by the belt&#39;s back surface  7  and the support system  84 . 
         [0081]    Since a flat belt  4  is defined as the type of belt having a back  7 , an outer cover  10  and a centerline belt path  83  that has its tracking controlled by the belt&#39;s back surface  7  and the support system  84 , the support system  84  must maintain this proper tracking characteristic while being articulated. To understand why the solutions claimed work it is important to understand the basic physics behind flat belt tracking. As shown in  FIGS. 12A and 12B , when a flat belt  4  is traveling around any generally cylindrical object with parallel surfaces such as a pulley  8  or roller  14 , the belt surface contact will naturally tend to track towards a direction  100  perpendicular to the surface of the contacting support surface and the back  7  of the flat belt  4 . In the case of the flat belt  4  on the parallel roller  14  shown in  FIG. 12A , the flat belt  4  will not have a tendency to shift laterally. Where as, in the case of a tapered roller  92  shown in  FIGS. 12C and 12D , the flat belt  4  will have a tendency to shift in the direction  101  perpendicular to the surface, thus in this case the centerline belt path  83  will gradually track towards the large end of the tapered roller  92 . This is the basic principle behind a crowned pulley  24  as shown in  FIGS. 3C ,  3 C′,  12 E,  12 F′,  12 F″ and  12 F′″. Since a crowned pulley has an outer diameter of the pulley  18 ′ which is variable across the length of the cylinder such that the outside diameter in the center of the cylinder  19  is larger than the outside diameter at the ends of the cylinder  19 ′, and typically is symmetrical. As a result, even though theoretically there is a gap as shown in FIG.  12 F′, in practice the flexible material of the flat belt  4  will conform to the crowned pulley&#39;s surface. The result is that there are opposing laterally shifting tendencies  102 ,  103 . The strength of these tendencies is generally a function of how much contact surface area exists between the flat belt  4  and the crowned surfaces  104 ,  105 . The more contact surface area, the larger the tendency. As a result, should the flat belt  4  laterally shift slightly such that contact surface area  104  is larger than contact surface area  105 , then the shifting tendency  102  which is associated with contact surface area  104  would grow relative to the shifting tendency  103  which is associated with contact surface area  105 . This imbalance in tendencies  102 ,  103  will cause the flat belt to shift back towards the middle thus giving the crowned pulley  24  the desired characteristic of keeping a flat belt  4  properly tracking to the center of the crowned pulley. It is important to note that there are a variety of crowned surfaces, including but not limited to a taper with and without a flat area in the middle and a multitude of curved surfaces. It is also important to note that the belting material and other system parameters can also affect the way a belt path tracks. 
         [0082]    As the purpose of this flat belt  4  is the application of conveyance  33 , the flat belt  4  may convey objects  38  from the entrance portion  86  of a conveyance surface  30  proximate a first roller  65  to the exit portion  87  of the conveyance surface  30  proximate a first pulley  67 . 
         [0083]    In the most basic form of the invention the support system  84  has three rotational elements. They are a first roller  65 , a first pulley  67  and a second pulley  68 . 
         [0084]    The first roller  65  has a rotational axis  59 , an outer surface  88  supporting the back  7  of the flat belt  4  and an entrance velocity plane  58  perpendicular to the rotational axis  59  which intersects the first roller average contact centerline belt path  96  which is the average lateral position of the centerline belt path  83  along the rotational axis  59  where the back  7  of the flat belt  4  is in contact with the first roller outer surface  88 . 
         [0085]    The first pulley  67  has a rotational axis  63  and an outer surface  89  supporting the back  7  of the flat belt  4  with an exit velocity plane  62  perpendicular to the rotational axis  63  which intersects the first pulley average contact centerline belt path  97  which is the average lateral position of the centerline belt path  83  along the rotational axis  63  where the back  7  of the flat belt  4  is in contact with the first pulley outer surface  89 . 
         [0086]    The second pulley  68  has a rotational axis  76  and an outer surface  91  supporting the back  7  of the flat belt  4  with a return velocity plane  75  perpendicular to the rotational axis  76  which intersects the second pulley average contact centerline belt path  99  which is the average lateral position of the centerline belt path  83  along the rotational axis  76  where the back  7  of the flat belt  4  is in contact with the second pulley outer surface  91 . 
         [0087]    The flat belt  4  and the most basic form of a support system  84  includes: the flat belt  4  has an upper conveyance surface  30  where the conveyance surface  30  has an entrance portion  86  and an entrance velocity plane  58  proximate the first roller  65 , the conveyance surface  30  has an exit portion  87  with an exit velocity plane  62  proximate the first pulley  67 , the first pulley  67  deflects the flat belt  4  from the entrance velocity plane  58  to the exit velocity plane  62 , the entrance velocity plane  58  and the exit velocity plane  62  are not coplanar and not parallel and the return velocity plane  75  is substantially coplanar with the exit velocity plane  62 . With the flat belt  4  tracking the second pulley  68 , the lateral positioning  47  of the second pulley  68  controls the lateral positioning of the entrance velocity plane  58 . With the flat belt  4  tracking the first pulley  67  and thereby controlling the position of the exit velocity plane  62 , the exit velocity plane  62  is adjustable to any selected degree of not coplanar and not parallel to the entrance velocity plane  61  by adjusting the position of the first pulley  67  and simultaneously adjusting the second pulley  68  in order to keep the return velocity plane  75  substantially coplanar with the exit velocity plane  62 . The first roller  65  is substantially wider than the flat belt  4  and thus the second pulley  68  can controlled the lateral position of the entrance velocity plane  58 . However, the first roller  65  must to rotating at a minimum speed in order to allow the belt to laterally shift thus the entrance velocity plane  61  is laterally  47  movable along the rotational axis  59  of the first roller  65  while rotating the first roller  65  to permit the flat belt  4  to maintain proper tracking of the second pulley  68 . In the preferred embodiment, the first pulley  67  and second pulley  68  are crowned  24  to improve the ability of the flat belt  4  to track the first and second pulleys  67 ,  68 . In the preferred embodiment the maximum degree to which the entrance velocity plane  58  and the exit velocity plane  62  can be not coplanar and not parallel can be increased while still maintaining proper tracking if the tracking tendencies of the first roller are not allowed to affect the tracking tendencies of the second pulley which can be minimized if spatial relationship exists between the first roller  65 , first pulley  67  and second pulley  68  such that the tangent surface vector  78  created by the first roller  65  and the first pulley  67  is substantially perpendicular to the tangent surface vector  79  created by the first roller  65  and the second pulley  68 . In order to convey objects  38 , in this most basic form of a support system  84  a torque source  94  is operatively connected to first roller  65  to provide driving power for the flat belt  4  through friction between the back  7  of the flat belt  4  and the outer surface  88  of the first roller  65 . 
         [0088]    The flat belt  4  and the preferred embodiment of a support system  85  would have additional angular belt contract surface with the various pulleys and rollers and it is often desirable to drive the flat belt  4  with a torque source  94  such that the cover  10  of the flat belt  4  is being driven since the cover  10  typically is of higher friction than the belt back  4 . In order to achieve this preferred embodiment of a support system  85  a second roller  66  having a rotational axis  72  and an outer surface  90  is positioned between the second pulley  68  and the first roller  65 , with the second roller rotational axis  72  parallel to the first roller rotational axis  59  such that the cover  10  of the flat belt contacts the surface  90  of the second roller  66  which increases the amount of surface contact between the first roller surface  88  and the back  7  of the flat belt  4  and increases the amount of surface contact between the second pulley surface  91  and the back  7  of the flat belt  4 . A torque source  94  is operatively connected to the second roller  66  to provide driving power for the flat belt  4  through friction between the cover  10  of the flat belt  4  and the outer surface  90  of the second roller  66 . In both support embodiments  84 ,  85 , the conveyance surface  30  conveys objects  38  from the entrance portion  86  proximate the first roller  65  to the exit portion  87  proximate the first pulley  67 . In applying this invention to the corrugated industry, in particular the production of flat boxes  41  by a die cutter  42 , the conveyed objects  38  are flat boxes  41 . 
         [0089]    As the purpose of a plurality of flat belts  4 ,  4 ′ is the application of conveyance  33 , each of the plurality of flat belts  4 ,  4 ′ may convey objects  38  from the entrance portion  86 ,  86 ′ of a conveyance surface  30 ,  30 ′ proximate a first roller  65  to the exit portion  87 ,  87 ′ of the conveyance surface  30  proximate each associated first pulley  67 . 
         [0090]    In the most basic form of the invention with a plurality of flat belts  4 ,  4 ′ for each support systems  84 ,  84 ′ there is one roller common to the plurality of flat belts  4 ,  4 ′ and support systems  84 ,  84 ′ and a plurality of first pulleys  67 ,  67 ′ and second pulleys  68 ,  68 ′ as elements in each of the support systems  84 ,  84 ′. 
         [0091]    The first roller  65  common to the plurality of flat belts  4 ,  4 ′ and support systems  84 ,  84 ′ has a rotational axis  59 , an outer surface  88  supporting the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ and an entrance velocity plane  58 ,  58 ′ perpendicular to the rotational axis  59  which intersects the first roller average contact centerline belt path  96 ,  96 ′ which is the average lateral position of the centerline belt path  83 ,  83 ′ along the rotational axis  59  where the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ is in contact with the first roller outer surface  88 . 
         [0092]    Each first pulley  67 ,  67 ′ has a rotational axis  63 ,  63 ′ and an outer surface  89 ,  89 ′ supporting the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ with an exit velocity plane  62 ,  62 ′ perpendicular to the rotational axis  63 ,  63 ′ which intersects the first pulley average contact centerline belt path  97 ,  97 ′ which is the average lateral position of the centerline belt path  83 ,  83 ′ along the rotational axis  63 ,  63 ′ where the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ is in contact with the first pulley outer surface  89 ,  89 ′. 
         [0093]    Each second pulley  68 ,  68 ′ has a rotational axis  76 ,  76 ′ and an outer surface  91 ,  91 ′ supporting the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ with a return velocity plane  75 ,  75 ′ perpendicular to the rotational axis  76 ,  76 ′ which intersects the second pulley average contact centerline belt path  99 ,  99 ′ which is the average lateral position of the centerline belt path  83 ,  83 ′ along the rotational axis  76 ,  76 ′ where the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ is in contact with the second pulley outer surface  91 ,  91 ′. 
         [0094]    In the most basic form of the invention with a plurality of flat belts  4 ,  4 ′ each flat belt  4 ,  4 ′ and associated support systems  84 ,  84 ′ includes: the flat belt  4 ,  4 ′ having an upper conveyance surface  30 ,  30 ′ where the conveyance surface  30 ,  30 ′ has an entrance portion  86 ,  86 ′ and an entrance velocity plane  58 ,  58 ′ proximate the first roller  65 , the conveyance surface  30 ,  30 ′ has an exit portion  87 ,  87 ′ with an exit velocity plane  62 ,  62 ′ proximate the first pulley  67 ,  67 ′, the first pulley  67 ,  67 ′ deflects the flat belt  4 ,  4 ′ from the entrance velocity plane  58 ,  58 ′ to the exit velocity plane  62 , the entrance velocity plane  58  and the exit velocity plane  62 ,  62 ′ which are not coplanar and not parallel and the return velocity plane  75 ,  75 ′ is substantially coplanar with the exit velocity plane  62 ,  62 ′. With the flat belt  4 ,  4 ′ tracking the second pulley  68 ,  68 ′, the lateral positioning  47  of the second pulley  68 ,  68 ′ controls the lateral positioning of the entrance velocity plane  58 ,  58 ′. With the flat belt  4 ,  4 ′ tracking the first pulley  67 ,  67 ′ and thereby controlling the position of the exit velocity plane  62 ,  62 ′, the exit velocity plane  62 ,  62 ′ is adjustable to any selected degree of not coplanar and not parallel to the entrance velocity plane  61 ,  61 ′ by adjusting the position of the first pulley  67 ,  67 ′ and simultaneously adjusting each associated second pulley  68  in order to keep each associated return velocity plane  75 ,  75 ′ substantially coplanar with each associated exit velocity plane  62 ,  62 ′. The first roller  65  is substantially wider than each flat belt  4 ,  4 ′ and thus the second pulley  68 ,  68 ′ can controlled the lateral position of the entrance velocity plane  58 ,  58 ′. However, the first roller  65  must to rotating at a minimum speed in order to allow the flat belts  4 ,  4 ′ to laterally shift thus each associated entrance velocity plane  61 ,  61 ′ is laterally  47  movable along the rotational axis  59  of the first roller  65  while rotating the first roller  65  to permit each associated flat belt  4 ,  4 ′ to maintain proper tracking of each associated second pulley  68 ,  68 ′. In the preferred embodiment, the plurality of first pulley  67  and plurality of second pulley  68  are crowned  24  to improve the ability of the plurality of flat belt  4  to track each associated first pulley  67 ,  67 ′ and second pulleys  68 ,  68 ′. In the preferred embodiment the maximum degree to which each entrance velocity plane  58 ,  58 ′ and each associated exit velocity plane  62 ,  62 ′ can be not coplanar and not parallel can be increased while still maintaining proper tracking if the tracking tendencies of the first roller  58  are not allowed to affect the tracking tendencies of the second pulley  68 ,  68 ′ which can be minimized if spatial relationship exists between the first roller  65 , each first pulley  67 ,  67 ′ and each second pulley  68 ,  68 ′ is such that the each associated tangent surface vector  78 ,  78 ′ created by the first roller  65  and each first pulley  67 ,  67 ′ is substantially perpendicular to the tangent surface vector  79 ,  79 ′ created by the first roller  65  and each associated second pulley  68 ,  68 ′. In order to convey objects  38 , in this the most basic form of the invention with a plurality of flat belts  4 ,  4 ′ each flat belt  4 ,  4 ′ and associated support systems  84 ,  84 ′ a torque source  94  is operatively connected to first roller  65  to provide driving power for each flat belts  4 ,  4 ′ through friction between the back  7 ,  7  of the flat belt  4 ,  4  and the outer surface  88  of the first roller  65 . 
         [0095]    In the preferred each flat belt  4  and support system  85 ,  85 ′ has additional angular belt contact surface with the various pulleys and rollers and it is often desirable to drive the flat belt  4 ,  4 ′ with a torque source  94  such that the cover  10 ,  10 ′ of the flat belt  4 ,  4 ′ is being driven since the cover  10 ,  10 ′ typically is of higher friction than the belt back  4 ,  4 ′. In order to achieve this preferred embodiment of a support system  85 ,  85 ′ a second roller  66  having a rotational axis  72  and an outer surface  90  is positioned between the second pulleys  68 ,  68 ′ and the first roller  65 , with the second roller rotational axis  72  parallel to the first roller rotational axis  59  such that the cover  10  of the flat belt contacts the surface  90  of the second roller  66  which increases the amount of surface contact between the first roller surface  88  and the back  7 ,  7 ′ of the flat belt  4 ,  4 ′ and increases the amount of surface contact between the plurality of each second pulley surface  91 ,  91 ′ and the back  7 ,  7 ′ of the flat belt  4 ,  4 ′. A torque source  94  is operatively connected to the second roller  66  to provide driving power for each flat belt  4 ,  4 ′ through friction between the cover  10 ,  10 ′ of each flat belt  4 ,  4 ′ and the outer surface  90  of the second roller  66 . In both support embodiments  94 ,  95 , the conveyance surface  30  conveys objects  38  from the entrance portion  86 ,  86 ′ proximate the first roller  65  to the exit portion  87 ,  87 ′ proximate the first pulley  67 . In applying this invention to the corrugated industry, in particular the production of flat boxes  41  by a die cutter  42 , the conveyed objects  38  are flat boxes  41 . 
         [0096]    The plurality of flat belts  4 ,  4 ′ and support systems  84 ,  84 ′ or the preferred embodiment plurality of flat belts  4 ,  4 ′ and support systems  95 ,  95 ′ have a direct application when integrated into a sheet stacking machine  54  which conveys flat boxes  41  for the purpose of producing stacks of boxes  50 . 
         [0097]    An articulation system  85  is required to articulate the elements of the support system  84 ,  84 ′,  95 ,  95 ′ There are a multitude of means by which this can be easily accomplished by those skilled in the art with the following example described for completeness. In the simplest form, the rollers and pulleys would be rigidly mounted on framework with fixturing such that each item could be manually positioned relative to each other. 
         [0098]    In an additional, for sophisticated example, is becomes clear that elements included in the basic support system  84 ,  84 ′ and the preferred embodiment support system  95 ,  95 ′ are only different in the added element of a second roller  66  for the preferred embodiment. Since the second roller  66  can be fixed to the frame  106  of a sheet stacker  54  as an example, the means for articulating the plurality of first pulleys  65 ,  65 ′ and second pulleys  67 ,  67 ′ will apply to all support systems  84 ,  84 ′,  95 ,  95 ′. 
         [0099]    A simple articulation system would include the following for each flat belt  4 ,  4 ′ and associated first pulley  65 ,  65 ′ and second pulley  67 ,  67 ′. A substantially rigid belt arm  107  would operatively connect each first pulley  65 ,  65 ′ and second pulley  67 ,  67 ′. These belt arms  107 ,  107 ′ would be pivotably connected to an entrance slider block  108 ,  108 ′ and supported by exit slider block  109 ,  109 ′. This slider block  108 ,  108 ′,  109 ,  109 ′ would be able to move selectively along entrance linear rail  110  and exit linear rail  111  respectively. This results in the belt arm pivoting about pivot point  80 . By implementing one of a multitude of means to control and position these slider blocks  108 ,  108 ′,  109 ,  109 ′, the articulation of the support systems  84 ,  84 ′,  95 ,  95 ′ may be achieved.

Technology Classification (CPC): 1