Patent Document

[0001]    This application claims priority from provisional application entitled VERTICAL DIVERTER ASSEMBLY, Ser. No. 60/265,976, filed Feb. 2, 2001, the disclosure of which is incorporated by reference herein in its entirety. 
     
    
     
       TECHNICAL FIELD AND BACKGROUND OF THE INVENTION  
         [0002]    The present invention generally relates to a device for transferring articles from a generally horizontal conveying surface to one of a plurality of vertically spaced conveying surfaces and, more particularly, to a high speed, high volume diverter which transfers articles with a substantially continuous throughput from a first conveyor section to one of two vertically spaced conveyors sections.  
           [0003]    In article-handling systems, including baggage handling systems, articles are conveyed along conveying surfaces, such as provided by belts, rollers or the like, and are conveyed along a conveyor path which may include one or more alternate conveyor paths for sorting the articles to be handled. In order to redirect or divert articles to the various conveyor paths, article-handling systems typically include diverters, such as horizontal and vertical diverters at each point of sortation. These diverters redirect the flow of the articles from one conveyor path to another for, as noted above, sorting the articles. Vertical diverters heretofore have typically not achieved a high-speed throughput since they typically require the packages conveyed on the conveyors to be spaced apart to allow the diverter time to align between the desired conveying surfaces of the conveyor sections. As a result, the package sortation speed is not optimized.  
           [0004]    Consequently, there is a need for a high-speed vertical diverter that increases the delivery and sortation speed of an article handling system by increasing the speed at which the diverter can direct the flow of articles.  
         SUMMARY OF THE INVENTION  
         [0005]    The present invention provides a vertical diverter assembly which selectively directs the flow of articles from a first generally horizontal surface to one of two vertically spaced conveying surfaces in a rapid fashion to increase the sortation speed and, hence, delivery speed of an article handling system.  
           [0006]    According to one form of the invention, a diverter assembly includes a frame and first and second driven conveying surfaces supported by the frame. The conveying surfaces are each adapted to move between a first position and a second position, with the first conveying surface being pivoted about its input end, and the second conveying surface being pivoted about its output end when pivoted between their respective first and second positions. In the first position, the conveying surfaces are aligned to define a first conveyor path for transporting articles from a first conveyor to a second conveyor. In the second position, the conveying surfaces define two separate conveyor paths, with the first driven conveying surface aligning between the first conveyor and a third conveyor positioned below the second conveyor to divert articles to the third conveyor, and the second driven conveying surface generally horizontally aligned with the second conveyor.  
           [0007]    In one aspect, driven belts provide the conveying surfaces. In a further aspect, at least one of the belts is driven by a motorized roller.  
           [0008]    In other aspects, the conveying surfaces are moved substantially simultaneously when moved between their first and second positions. Furthermore, the belts maybe continuously driven so as to maintain the flow of articles along the conveying path.  
           [0009]    According to a further aspect, the first driven conveying surface is driven by a motorized roller at its input end, with first driven conveying surface being pivoted about the pivot axis of the motorized roller when the first driven conveying surface is moved between its first and second positions. In another aspect, a motorized roller at the output end drives the second driven conveying surface, with the second driven conveying surface being pivoted about the pivot axis of the motorized roller of the second driven conveying surface when the second driven conveying surface is moved between its first and second positions.  
           [0010]    According to another aspect, the diverter assembly includes first and second conveyor sections, which include the first and second driven conveying surfaces, respectively. The first and second conveyor sections are interlinked whereby pivotally movement of one of the conveyor sections induces pivotal movement of the other conveyor section to thereby move the conveying surfaces between their respective first and second positions. In other aspects, the first and second conveyor sections pivot about the input end and the output end, respectively, when the conveying surfaces are pivoted between their first and second positions.  
           [0011]    In yet other aspects, each of the first and second conveyor sections includes spaced apart sides on opposed sides of its respective conveying surface, which provide guides for articles conveyed on the conveying surfaces. For example, the sides may comprise generally vertical sides. Furthermore, the sides provide substantially continuous guide surfaces when the conveying surfaces are at their first positions and/or when the conveying surfaces are in their second positions. In order to minimize the interference between the sides when the conveying surfaces are moved between their first and second positions, at least one pair of the sides includes flexible panels. Preferably, each of the sides includes a flexible panel to minimize the interference between the sides.  
           [0012]    According to another form of the invention, a diverter assembly includes a frame and first and second conveyor sections pivotally supported by the frame, with each conveyor section having a driven conveying surface. The conveyor sections are each adapted to pivot between a first position and a second position. In the first position, their conveying surfaces are aligned to define a first conveyor path for transporting articles from a first conveyor to a second conveyor. In the second position, the conveying surfaces are pivoted to a generally horizontal position to define two separate conveyor paths, with the conveying surface of the first conveyor section aligning between the first conveyor and a third conveyor positioned below the second conveyor to divert articles to the third conveyor, and the second conveying surface generally horizontally aligned with the second conveyor.  
           [0013]    In one aspect, the conveyor sections are linked together such that rotation of the first conveyor section induces rotation of the second conveyor section. For example, rods may link the first and second conveyor sections.  
           [0014]    In other aspects, each of the conveyor sections includes vertical guide surfaces to guide the articles being transported along the conveying surfaces of the conveyor sections.  
           [0015]    In other aspects, the first conveyor section is pivoted about its input or charge end when it is moved between its first and second positions. The second conveyor section, in contrast, is pivoted about its discharge or output end when it is moved between its first and second position. Optionally, the conveyor sections are moved substantially simultaneously when moved between their first and second positions. Furthermore, the conveying surfaces are continuously driven so as to maintain the flow of articles along the conveying path.  
           [0016]    In yet another form of the invention, the diverter assembly includes a frame, which is positionable between a first conveyor and a second conveyor, and means for conveying articles. The means for conveying is supported by the frame and is configured to switch between defining a first conveyor path for transporting articles from the first conveyor to the second conveyor and defining second and third conveyor paths, with the second conveyor path for diverting articles to a third conveyor below the second conveyor, and the third conveyor path for generally aligning with the second conveyor. The assembly further includes a control for switching the means for conveying.  
           [0017]    In one aspect, the means for conveying comprises a pair of driven belts. In other aspects, the means comprises first and second conveyor sections, with the first conveyor section having a first conveying surface, and the second conveyor section having a second conveying surface. The first conveying surface pivots about a first pivot axis to move the first conveying surface between the first conveyor path and the second conveyor path. The second conveying surface pivots about a second pivot axis to move between the first conveyor path and the third conveyor path.  
           [0018]    A method of diverting articles of the present invention includes conveying an article on a conveying surface along a first conveyor path between a first conveyor and a second conveyor, supporting the conveying surface by a frame, pivoting a first portion of the conveying surface about the frame to define a second conveyor path whereby the first portion is generally aligned between the first conveyor and a third conveyor, and pivoting a second portion of the conveying surface about the frame to a third conveyor path whereby the second portion is generally aligned with the second conveyor.  
           [0019]    The present invention provides an improved diverter assembly that exhibits increased throughput of articles, such as baggage, thus increasing the capacity of an article handling system that incorporates the diverter assembly of the present invention.  
           [0020]    These and other objects, advantages, purposes, and features of the invention will become more apparent from the study of the following description taken in conjunction with the drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]    [0021]FIG. 1 is a front perspective view of a vertical diverter assembly of the present invention illustrating the two conveying surfaces of the diverter aligned to define a single conveying path;  
         [0022]    [0022]FIG. 2 is a perspective view of the diverter assembly of FIG. 1 illustrating the conveying surfaces of the diverter moved to a second orientation such that the lower conveying surface is aligned for aligning with a lower conveyor section, and the upper conveying surface is aligned with an upper conveyor section;  
         [0023]    [0023]FIG. 3 is a front elevation view of the diverter assembly of FIG. 1;  
         [0024]    [0024]FIG. 4 is a side elevation view of the diverter assembly of FIG. 3;  
         [0025]    [0025]FIG. 5 is a top plan view of the diverter assembly of FIGS. 3 and 4;  
         [0026]    [0026]FIG. 6 is a front perspective view of a lower tilting conveyor section of the diverter assembly;  
         [0027]    [0027]FIG. 7 is a front perspective of the upper tilting conveyor surface;  
         [0028]    [0028]FIG. 8 is a side elevation view of the lower conveying surface of FIG. 6;  
         [0029]    [0029]FIG. 9 is a top plan view of the conveying surface of FIG. 8;  
         [0030]    [0030]FIG. 10 is a side elevation view of the upper conveying surface of FIG. 7;  
         [0031]    [0031]FIG. 11 is a top plan view of the conveying surface of FIG. 14;  
         [0032]    [0032]FIG. 12 is an exploded perspective view of the lower conveying surface of FIG. 6;  
         [0033]    [0033]FIG. 13 is an exploded perspective view of the upper conveyor surface of FIG. 7;  
         [0034]    [0034]FIG. 14 is a front perspective view of the frame of the diverter assembly of FIGS.  1 - 5 ;  
         [0035]    [0035]FIG. 15 is a front elevation view of the vertical frame assembly of FIG. 10;  
         [0036]    [0036]FIG. 16 is a top plan view of the frame assembly of FIGS.  10 - 12 ;  
         [0037]    [0037]FIG. 17 is a side elevation view of the frame assembly of FIGS. 10 and 11;  
         [0038]    [0038]FIG. 18 is a perspective view of the drive mechanism of the diverter assembly;  
         [0039]    [0039]FIG. 19 is a top plan view of the driver assembly of FIG. 18; and  
         [0040]    [0040]FIG. 20 is a side elevation view of the driver assembly of FIG. 19. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0041]    Referring to FIGS.  1 - 5 , the numeral  10  generally designates a vertical diverter assembly of the present invention. Diverter assembly  10  includes a frame  12  and upper and lower conveyor sections  14  and  16 . Conveyor sections  14  and  16  include upper and lower conveying surfaces  18  and  20  defined by conveyor belts  19  and  21 , respectively. Diverter assembly  10  comprises a modular diverter assembly which can be placed between the discharge end of a first conveyor section  22  and the charge ends of two vertically spaced conveyor sections  24  and  26  for diverting packages from the conveyor path defined between conveyor sections  22  and  26  to the conveyor path defined between conveyor sections  22  and  24 . As will be more fully described below, conveyor sections  14  and  16  are movable between a first orientation (shown in FIG. 1) in which their respective conveying surfaces are aligned to provide a co-linear conveying surface or conveyor path for directing packages to upper conveyor section  24  and a second position in which lower conveying surface  20  is moved to a generally horizontal position to align with and direct packages to lower conveyor section  26  (FIG. 2), while upper conveying surface  18  is moved to a generally horizontal position to align with conveyor section  24 .  
         [0042]    Referring to FIG. 6, lower conveyor section  16  includes a frame  30  that supports conveyor belt  21 . Frame  30  includes a pair of spaced apart, opposing vertical sides  32  and  34  and a belt support  39 . Sides  32  and  34  provide vertical guide surfaces for articles being transported by belt  21 . Referring to FIG. 8, belt support  39  comprises a plurality of transverse frame members  40  and upper plate members  42 , which are supported by transverse frame members  40 . Plate members  42  and transverse frame members  40  are mounted to sides  32  and  34 , such as by welding. Frame  30  supports a pair of rollers  36  and  38 , which are mounted to frame  30  at opposed ends of belt support  39 . Referring again to FIG. 8, upper plate members  42  extend between rollers  36  and  38  and are generally aligned with the upper surfaces of rollers  36  and  38  to provide substantially continuous support to belt  21 . Belt  21  comprises a closed loop belt that extends over rollers  36  and  38  and over belt support  39  to define lower conveying surface  20 . Roller  36  is mounted to the charge or input end of conveyor section  16  and is motorized to drive belt  21 . Suitable motorized rollers are available from Vandergraaf of Toronto, Canada. Roller  38  comprises an idler roller and is mounted to the output end or discharge end of conveyor section  16 .  
         [0043]    Mounted to the input end of sides  32  and  34  are rocker arms  46  and  48 . As will be more fully described in reference to drive assembly  130 , crank or rocker arms  46  and  48  pivot conveyor section  16  about frame to move conveyor section  16  from its first position, in which conveyor surface  20  is aligned with conveyor surface  18 , and its second position in which conveyor surface  20  is aligned with conveyor section  26  (FIG. 2). In the illustrated embodiment, roller  36  includes rod ends  50  which are supported in C-shaped blocks  51  mounted in slotted openings  32   a  and  34   a  of sides  32  and  34  and in corresponding slotted openings  46   a  and  48   b  of rocker arms  46  and  48 . Rod ends  50  are rotatably mounted in blocks  51  by clamp bars  51   a,  which are secured to C-shaped blocks  51  by fasteners  51   b.  Aligned with rods  50  is a pair of mounting collars  52 . Each mounting collar  52  includes a mounting flange  52   b , through which fasteners  52   a  extend to mount mounting collar  52  onto a respective rocker arm  46 ,  48 , and a pivot cylinder  52   c . Pivot cylinders  52   c  mount lower conveyor section  16  in frame  12 , as will be more fully described in reference to FIGS.  14 - 17 . Therefore, when rocker arms  46  and  48  are pulled or pushed by drive assembly  130 , lower conveyor section  16  will pivot about pivot cylinder  52   c  and also about the rotational axis  36   a  of pulley  36 . In order to provide adjustment for the tension on belt  21 , at least pulley  38  is mounted to side frame members  32  and  34  in a slotted opening  32   b ,  34   b  with its respective rod extending into a roller adjuster  54 . Roller adjuster  54  provides linear adjustment of pulley  38  to increase or decrease the tension on belt  21  as will be understood by those skilled in the art.  
         [0044]    Referring to FIG. 7, upper conveyor section  14  similarly includes a frame  60  that supports belt  19 . Frame  60  includes a pair of opposed, spaced apart sides  62  and  64  and a belt support  69 . Sides  62  and  64  similarly provide generally vertical guide surfaces for article being conveyed on belt  19 . In addition, sides  62  and  84  preferably align with sides  32  and  34  when conveyor sections  14  and  16  are pivoted to their first position (FIG. 1). In order to minimize interference between sides  62 ,  64  and  32 ,  34 , sides  32  and  34  may include flexible extensions or panels  33  and  35  (FIG. 1), which deflect as needed to accommodate potential interference between the sides. However, extensions  33  and  35  should have sufficient stiffness to provide continuous vertical guide surfaces for the articles being transported between the sides.  
         [0045]    Mounted between side frame members  62  and  64  are a pair of rollers  66  and  68 . Roller  68  is mounted to discharge end of conveyor section  14  and comprises a motorized roller with a drum motor to drive belt  19 . Preferably, both rollers  36  and  68  continuously drive belts  19  and  21  so as to maintain the flow of articles along the conveying path, whether it is defined between conveyor  22 , conveyor section  16 , and conveyor  26  or between conveyor  22 , conveyor sections  14 ,  16 , and conveyor  24 . Roller  66  comprises an idler roller and is mounted to charge or input end of conveyor section  14 . Referring to FIG. 10, belt support  69  is of similar construction to belt support  39  and includes a plurality of transverse members  80  which extend transversely between sides  62  and  64  and which are mounted thereto, for example, by welding. Extending over transverse members  80  is a pair of plate members  82 . Again referring to FIG. 10, plate members  82  generally align with the upper surface of rollers  66  and  68  to provide continuous support for belt  19  and are secured to sides  62  and  64 , such as by welding or the like.  
         [0046]    Referring again to FIG. 7, upper conveyor section  14  includes a pair of rocker arms  86  and  88  that are mounted to side frame members  62  and  64 . Similarly, referring to FIG. 13, rod ends  90  of roller  68  are supported in C-blocks  91  mounted in slotted openings  62   a  and  64   a  of sides  62  and  64  and slotted openings  86   a  and  88   a  of rocker arms  86  and  88 . Rod ends  90  are rotatably mounted in blocks  91  by clamp bars  91   a  that secure to blocks  91  by fasteners  91   b . Similar to conveyor section  16 , conveyor section  14  includes a pair of mounting collars  92  mounted to sides  82  and  84  at rocker arms  86  and  88 , which are aligned with rod ends  90  of roller  68 . Mounting collars  92  include a mounting flange  92   a , which is secured to rocker arms  86  and  88  by fasteners, and a pivot cylinder  92   c , which is journaled in frame  12  to provide a pivot joint for conveyor section  14 , as will be more fully described below. Thus, when rocker arms  82  and  88  are pivoted, upper conveyor section  14  will pivot about rotational axis  68   a  of roller  68 .  
         [0047]    Referring to FIGS.  14 - 17 , frame  12  includes base frame members  100 ,  102 , which are interconnected by a medial transverse member  104  and a transverse plate member  106  that provides a cover for at least a portion of the drive assembly  130 , which will be more fully described below in reference to FIGS.  18 - 20 . Frame  12  further includes a plurality of vertical frame members  108   a ,  108   b ,  108   c , and  110   a ,  110   b ,  110   c , which are mounted to base frame members  100 ,  102  and which are secured to and provide support for side rails  112  and  114 . Side rails  112  and  114  each include a pair of roller mounts  116 ,  118 ,  120 ,  122 , respectively, at their opposed ends in which upper and lower conveyor sections  14 ,  16  are mounted by pivot cylinders  52   c  and  92   c  of mounting collars  52  and  92 , respectively. In the illustrated embodiment, frame  12  is assembled using conventional structural members, such as rectangular tubing; however, it should be understood that frame  12  may be assembled using other structural members. Furthermore, the structural members forming frame  12  may be connected using fasteners, welds or rivets as is conventionally known. In the illustrated embodiment, roller mounts  116 ,  118 ,  120 , and  122  comprise plate members  124  with transverse openings  126 , with pivot cylinders  52   c  and  92   c  journaled in openings  126  to define pivot axes for conveyor sections  14  and  16 . Plate members  124  are secured to rail members  112  and  114 , for example by fasteners. However, it should be understood that roller mounts  116 ,  118 ,  120 , and  122  may be mounted to rail members  112  and  114  by rivets or welds or the like. In addition, frame  12  optionally includes threaded, leveling feet  129  mounted to base frame members  100  and  102  that provide adjustment and leveling for diverter assembly  10 .  
         [0048]    Referring again to FIGS. 1 and 2 and as noted above, cylindrical members  52   c  and  92   c  of mounting collars  52  and  92  extend into roller mounts  116 ,  118 ,  120 , and  122  to thereby pivotally mount upper and lower conveyor sections  14  and  16  on frame  12  so that conveyor sections  14  and  16  can be pivoted about axes  36   a  and  68   a  to move conveying surfaces  18  and  20  between their two positions shown in FIGS. 1 and 2. Conveyor sections  14  and  16  are moved about pivot axes  36   a  and  68   a  by a drive assembly  130 .  
         [0049]    Referring to FIGS.  1 - 4  and  18 - 20 , drive assembly  130  includes a motor  132  and a drive shaft  134 . Motor  132  is coupled to drive shaft  134  by a belt  136  that extends around the output drive pulley  138  of motor  132  and over a timing pulley  140 , which is mounted to drive shaft  134 . In addition, in the illustrated embodiment, drive assembly  130  includes a clutch brake  141 , such as is available form Warner, which provides a brake and further permits disengagement of motor  132  from drive shaft  134  in the event of a jam or the like. Referring to FIG. 18, clutch brake  141  is supported by a clutch brake plate  141   a . As best understood from FIG. 15, clutch brake plate  141   a  rests on and is supported by a transverse support  135 , which extends between and is mounted to base frame members  102 . Shaft  134  is supported by a pair of bearing blocks  150 , such as pillow blocks, which in turn mount to supports  152 , such as angle members, that are secured to plate member  106  between vertical frame members  108   a  and  110   a  by fasteners, welds, rivets or the like. Mounted to opposed ends of drive shaft  134  is a pair of crankshaft assemblies  142 . Crank shaft assemblies  142  each include a crank disk  144  and crank pin  146  that is mounted to crank disk  144  offset from the rotational axis  134   a  of drive shaft  134 . Referring to FIGS. 1, 2 and  4 , crank pins  146  are coupled to rocker arms  46  and  48  of lower conveyor section  16  by tie rods  150 , which are mounted to distal end portions  46   a  and  48   a  of rocker arms  46  and  48 . Rocker arms  46  and  48  are interconnected by tie rods  150   a  and  150   b  (FIG. 12), which extend through rockers arms  46  and  48  to provide mounts for tie rods  150 . In this manner, when tie rods  150  push or pull on rocker arms  46 ,  48 , conveyor section  16  pivots about axis  36   a.    
         [0050]    As best seen in FIG. 1, when crank disks  142  rotated such that crank pins  146  are positioned at a three o&#39;clock position (as viewed in FIG. 1), lower conveyor section  16  is rotated upwardly. As best seen in FIG. 4, medial portions of rocker arms  46  and  48  are connected to the respective lower portions of rocker arms  86  and  88  by tie rods  154 . Rocker arms  86  and  88  are interconnected by a tie rod  154   a , which projects through rocker arms  86  and  88  to provide mounts for tie rods  154 . In this manner, when rocker arms  46  and  48  are rotated about rotational axis  36   a  of roller  36  by the movement of tie rods  150 , rocker arms  86  and  88  simultaneously pivot upper conveyor section  14  to align with lower conveyor section  16 . In this manner, conveying surfaces  20  and  18  define a substantially continuous path for article which is to be diverted from the generally horizontal conveying path defined between conveyor sections  22  and  26  to the second conveying path defined between conveyor section  22  and  24 . Similarly, when crank disks  142  are rotated in a clockwise direction to move crank pin  146  to the nine o&#39;clock position, tie rods  150  push on distal portions  46   a  and  48   a  of rocker arms  46  and  48  to pivot lower conveyor section  16  to a generally horizontal position as shown in FIG. 2. At the same time, tie rods  154  pull on lower portion of rocker arms  86  and  88  to pivot upper conveyor section  14  upwardly so that as shown in the illustrated embodiment, conveying surface  18  is generally aligned with the conveying surface of conveyor section  24 . In this manner, articles, which are supported on conveying surface  18 , may be continued to be processed and directed to conveyor section  24  while articles on conveying surface  20  may be continued to be carried and processed on conveying surface  20  of lower conveyor section  16  for delivery to conveyor section  26 .  
         [0051]    It can be appreciated from the foregoing that the diverter assembly of the present invention provides a diverter that can sort articles at varying speeds, including sortation speeds for articles, such as luggage, of at least 30 bags per minute, including 40 bags per minute.  
         [0052]    While one form of the invention has been shown and described, other forms or modifications will now be apparent to those skilled in the art. For example, conveyor sections  14 ,  16  may comprise roller conveyor sections. In addition, one or more external motors may drive rollers  36  and  68 . Furthermore, the structural members comprising the assembly frame ( 12 ) and frames  30 ,  60  for conveyor sections  14 ,  16  may be substituted with other conventional structural components.  
         [0053]    While several forms of the invention have been shown and described, other forms will now be apparent to those skilled in the art. For example, as noted, the diverter assembly may incorporate a single driver to drive both belts or may incorporate a driver for each belt. Furthermore, each conveyor section may be pivoted by its own driver. The present invention also has application with rollers defining the conveying surface of the diverter assembly. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the invention, which is defined by the claims, which follow as interpreted under the principles of patent law including the doctrine of equivalents.

Technology Category: 7