Patent Description:
Cross-belt conveyor systems include multiple carts that move along a track. Each cart includes its own individual belt conveyor that parcels on cart can be moved to the left of right as the cart moves along the track. Prior art document <CIT> shows a conveyor system comprising two spaced rails, each made up of four side panels forming a rectangular enclosed shape, on top of box shaped frames, also made up of four side panels, and a cart with vertical wheels which are supported on a top plate of the rails and two horizontal wheels which are supported on a inner side plates of the rails. Two horizontal wheels of the cart are supported on the inward facing side panels of the rails. Typically, each cart includes wheels which run along rails forming the track. The rails generally used for a typical cross-belt conveyor system are made from aluminum, which has its own advantages such as malleability and easier connection with a wide variety of bolts. However, with aluminum rails, the wheels of the carts can experience significant wear at the point of contact of between wheels and the rail. One known means of solving this problem is to place a sheet of steel above the aluminum rail at the point of contact.

The present invention relates to a conveyor system according to independent claims <NUM>, <NUM> and <NUM>.

One exemplary conveyor system made in accordance with the present invention comprises a track, which includes a variety of turns and changes in elevation. Multiple carts move along the track. Each cart includes vertical wheels and horizontal wheels which engage the track. In particular, a first set of wheels engages the first (or inner) rail, and a second set of wheels similarly engages the second (or outer) rail.

The invention according to claim <NUM> includes a top panel, a first (or inner) side panel, a second (or outer) side panel, and a bottom panel, such that the rail defines a substantially enclosed inner space. A vertical wheel of the cart is supported by the top panel of the rail, and a horizontal wheel of the cart engages the first side panel. More specifically, the first side panel defines a first (or wheel) channel within which the horizontal wheel of the cart is retained.

In the invention according to claim <NUM>, the cart is also electrically connected to the rail. In particular, the cart further includes an arm that extends downward from the base of the cart. At the end of the arm are multiple current collectors, each of which engage a respective connector rail extending around the track.

To this end, the first side panel of the rail further defines a second (or bolt) channel that extends along the length of the rail. A clamp is secured to the rail by a bolt within the bolt channel. Each of the multiple connector rails is secured to the rail by the clamp. The connector rails extend along substantially the entire length of the rail around the entirety of the track. Multiple clamps are spaced along the length of the rail to adequately secure the connector rails to the rail. In one particular embodiment, the clamps are spaced about one meter (<NUM>) apart along the track. In this way, as a cart moves around the track, the current collectors of the cart remain in contact with the connector rails to thereby maintain electrical connection between electronic devices on the cart and external electronic devices.

Similar to the first side panel, the second side panel and the bottom panel each define a respective bolt channel that extends along the length of the rail (i.e., around the track). In some implementations, the bolt channels of the second side panel and the bottom panel are used to connect the rail to a support frame of the conveyor system with bolts. However, the bolt channels of the second side panel and the bottom panel could also be used to attach other accessories (e.g., sensors or controllers) to the rail. In other words, the bolt channels provide a connection point to the rail along the entire length of the track.

In some embodiments, the first and second rails are substantially identical, but a mirror images. In certain embodiments, only one rail includes the clamps and plurality of connector rails. In other embodiments, however, both rails can include similar clamps and plurality of connector rails.

Another exemplary rail is comprised of two substantially identical members that are connected to form the rail. In particular, a first member includes a first panel, a second panel opposite the first panel, a third panel that extends between the first panel and the second panel, and a fourth panel that extends between the first panel and the second panel opposite from the third panel. Each of the panels is substantially flat, except the first panel includes a projection, and the fourth panel defines a channel, as discussed further below.

The second member similarly includes a first panel with a projection, a second panel opposite the first panel, a third panel that extends between the first panel and the second panel, and a fourth panel that extends between the first panel and the second panel opposite from the third panel and which defines a channel.

In some embodiments, the second member is a mirror image of the first member, and the first panel of the second member is connected (e.g., welded) to the first panel of the first member to thereby form an intermediate panel that bifurcates the inner space of the rail. The projection of the first panel of the first member and the projection of the first panel of the second member facilitate in the welding of the first member to the second member.

The second panel of the second member forms a top panel of the rail upon which a vertical wheel of the cart is supported. The fourth panel of the first member and the fourth panel of the second member collectively form a first (or inner) side panel of the rail with the channel of the fourth panel of the second member retaining a horizontal wheel of the cart.

The intermediate panel of the rail increases the rigidity of the rail which provides a greater bending radius for the rail. In some embodiments, the rail has a bending diameter of about <NUM> for horizontal turns in the track and can provide an angle of inclination at elevation changes in the track of about <NUM>°. The rail can therefore be used for any section of the track including a horizontal curve, an elevation change, or where both a horizontal curve and elevation change occurs simultaneously on the track.

Regardless of the particular configuration, in some embodiments, the rails of the present invention are made of cold-rolled steel. In some embodiments, the rails are made of stainless steel. This provides an improvement over aluminum rails which cause wear in the wheels of each cart at the point of contact between the wheels and the rail without also requiring any additional protection at this point of contact.

The present invention relates to a conveyor system that includes multiple carts that move along a track, for example a cross-belt conveyor system. The track typically includes two parallel rails to support the wheels of each cart.

Referring first to <FIG>, an exemplary conveyor system <NUM> made in accordance with the present invention comprises a track <NUM>, which includes a variety of turns and changes in elevation. The conveyor system <NUM> further includes multiple carts <NUM> that move along the track <NUM> and one or more feeder belts <NUM> that provide parcels onto the carts <NUM>. The carts <NUM> then deposit these parcels into one or more sorter bins <NUM>.

Referring now to <FIG> and <FIG>, and with respect to the carts <NUM> of the present invention, an exemplary cart <NUM> includes a base <NUM> with a belt conveyor <NUM> connected to the top of the base <NUM>. The belt conveyor including rollers <NUM> and a belt <NUM> which operate in a direction perpendicular to the direction of travel of the base <NUM> along the track <NUM>. As such, while the cart <NUM> moves along the track <NUM>, the conveyor <NUM> can readily accept parcels from the feeder belts <NUM> on either side of the cart <NUM> and deposit the parcels into the sorter bins <NUM> on either side of the cart <NUM>.

The cart <NUM> further includes vertical wheels <NUM> (shown only in <FIG>) and horizontal wheels <NUM> which engage the track <NUM>. In particular, as shown in <FIG>, the track <NUM> includes a first (or inner) rail <NUM> and a second (or outer) rail <NUM> which run parallel to one another. A first set of wheels <NUM>, <NUM> engages the first rail <NUM> and a second set of wheels <NUM>, <NUM> similarly engages the second rail <NUM>. Each of the first and second rails <NUM>, <NUM> is supported by a support frame <NUM>, as discussed further below.

Referring now to <FIG> and <FIG>, and with respect to the first rail <NUM> in particular, the exemplary first rail <NUM> includes a top panel <NUM>, a first (or inner) side panel <NUM>, a second (or outer) side panel <NUM>, and a bottom panel <NUM>, such that the first rail <NUM> defines a substantially enclosed inner space. A vertical wheel <NUM> of the cart <NUM> is supported by the top panel <NUM> of the first rail <NUM>, and a horizontal wheel <NUM> of the cart <NUM> engages the first side panel <NUM>. More specifically, the first side panel <NUM> defines a C-shaped first (or wheel) channel <NUM> within which the horizontal wheel <NUM> of the cart <NUM> is retained.

Referring still to <FIG> and <FIG>, the cart <NUM> is also electrically connected to the first rail <NUM>. In particular, the cart <NUM> further includes an arm <NUM> that extends downward from the base <NUM> of the cart <NUM>. At the end of the arm <NUM> are multiple (three) current collectors 452a, 452b, 452c which engage a respective connector rail 272a, 272b, 272c extending around the track <NUM>.

To this end, the first side panel <NUM> of the first rail <NUM> further defines a second (or bolt) channel <NUM> that extends along the length of the first rail <NUM>. A clamp <NUM> is secured to the first rail <NUM> by a bolt <NUM> within the bolt channel <NUM>. Each of the multiple (three) connector rails 272a, 272b, 272c is thereby secured to the first rail <NUM> by the clamp <NUM>. Although not expressly shown, the connector rails 272a, 272b, 272c extend along substantially the entire length of the first rail <NUM> around the entirety of the track <NUM>. Multiple clamps <NUM> are spaced along the length of the first rail <NUM> to adequately secure the connector rails 272a, 272b, 272c to the first rail <NUM>. In one particular embodiment, the clamps <NUM> are spaced about one meter (<NUM>) apart along the track <NUM>. Of course, the particular spacing of the clamps <NUM> can be modified according to the particular configuration and requirements of the track <NUM>. In this way, as the cart <NUM> moves around the track <NUM>, the current collectors 452a, 452b, 452c of the cart <NUM> remain in contact with the connector rails 272a, 272b, 272c to thereby maintain electrical connection between electronic devices on the cart <NUM> and external electronic devices.

Similar to the first side panel <NUM>, the second side panel <NUM> and the bottom panel <NUM> each define a respective bolt channel <NUM>, <NUM> that extends along the length of the first rail <NUM> (i.e., around the track <NUM>). In the embodiment shown in <FIG> and <FIG>, the bolt channels <NUM>, <NUM> of the second side panel <NUM> and the bottom panel <NUM> are used to connect the first rail <NUM> to the support frame <NUM> of the conveyor system <NUM> with bolts <NUM>, <NUM>. However, the bolt channels <NUM>, <NUM> of the second side panel <NUM> and the bottom panel <NUM> could also be used to attach other accessories (e.g., sensors or controllers) to the first rail <NUM>. In other words, the bolt channels <NUM>, <NUM> provide a connection point to the first rail <NUM> along the entire length of the track <NUM>.

The second rail <NUM> is substantially identical to the first rail <NUM>, but a mirror image thereof. In the embodiment shown in <FIG>, only the first rail <NUM> includes the clamp <NUM> and plurality of connector rails 272a, 272b, 272c. In other embodiments, however, the second rail <NUM> can also include a clamp and plurality of connector rails either instead of, or in addition to, the clamp <NUM> and plurality of connector rails 272a, 272b, 272c connected to the first rail <NUM>.

Referring now to <FIG>, in another exemplary embodiment, two substantially identical members are connected to form a rail <NUM> (i.e., either the first rail and/or the second rail). The exemplary rail <NUM> shown in <FIG> includes a first member 301a and a second member 301b. The first member 301a includes a first panel 302a, a second panel 304a opposite the first panel 302a, a third panel 306a that extends between the first panel 302a and the second panel 304a, and a fourth panel 308a that extends between the first panel 302a and the second panel 304a opposite from the third panel 306a. Each of the panels 302a, 304a, 306a, 308a is substantially flat, except the first panel 302a includes a projection 303a, and the fourth panel 308a defines a channel 309a, as discussed further below.

The second member 301b similarly includes a first panel 302b with a projection 303b, a second panel 304b opposite the first panel 302b, a third panel 306b that extends between the first panel 302b and the second panel 304b, and a fourth panel 308b that extends between the first panel 302b and the second panel 304b opposite from the third panel 306b and which defines a channel 309b.

As shown in <FIG>, the second member 301b is a mirror image of the first member 301a, and the first and second members 301a, 301b are connected to form the rail <NUM>. In particular, the first panel 302b of the second member 301b is connected (e.g., welded) to the first panel 302a of the first member 301a to thereby form an intermediate panel <NUM> of the rail <NUM> that bifurcates the inner space of the rail <NUM>. The projection 303a of the first panel 302a of the first member 301a and the projection 303b of the first panel 302b of the second member 301b facilitate in the welding of the first member 301a to the second member 301b.

The second panel 304b of the second member 301b forms a top panel <NUM> of the rail <NUM> upon which a vertical wheel of the cart (not shown) is supported in substantially the same manner as the top panel <NUM> of the first rail <NUM> described above with respect to <FIG> and <FIG>. The fourth panel 308a of the first member 301a and the fourth panel 308b of the second member 301b collectively form a first (or inner) side panel <NUM> of the rail <NUM> with the channel 309b of the fourth panel 308b of the second member 301b retaining a horizontal wheel of the cart (not shown) in substantially the same manner as the first side panel <NUM> of the first rail <NUM> described above with respect to <FIG> and <FIG>.

It is contemplated that the rails <NUM>, <NUM> shown in <FIG> are preferably used in straight sections of the track <NUM>, whereas the rail <NUM> shown in <FIG> is preferably used in curved sections of the track <NUM>. To this end, the overall shape of the rail <NUM> shown in <FIG> is designed to be substantially the same as the shape of the rails <NUM>, <NUM> shown in <FIG>, such that a cart <NUM> can easily transition between those portions of the track <NUM> formed of the rails <NUM>, <NUM> shown in <FIG> and those portions of the track <NUM> formed of the rail <NUM> shown in <FIG>.

With respect to the use of the rail <NUM> shown in <FIG> in curved sections of the track <NUM>, the intermediate panel <NUM> of the rail <NUM> shown in <FIG> increases the rigidity of the rail <NUM> as compared to the rails <NUM>, <NUM> shown in <FIG>. This provides a greater bending radius for the rail <NUM> shown in <FIG>. In some embodiments, the rail <NUM> shown in <FIG> has a bending diameter of about <NUM> for horizontal turns in the track <NUM> and can provide an angle of inclination at elevation changes in the track <NUM> of about <NUM>°. The rail <NUM> can therefore be used for any section of the track <NUM> including a horizontal curve, an elevation change, or where both a horizontal curve and elevation change occurs simultaneously on the track <NUM>.

Claim 1:
A conveyor system (<NUM>) including a cart (<NUM>) that moves along a rail (<NUM>, <NUM>), the rail comprising:
a top panel (<NUM>) upon which a vertical wheel (<NUM>) of the cart (<NUM>) is supported;
a first side panel (<NUM>) defining a C-shaped channel (<NUM>) within which a horizontal wheel (<NUM>) of the cart (<NUM>) is retained; and
one or more connector rails (272a, 272b, 272c) extending along the rail (<NUM>, <NUM>), the cart electrically connected to the one or more connector rails.