Differential speed conveyor accumulation system and method

Abstract

A product conveying and accumulation system and method employs a primary product transporting conveyor with accumulation and re-circulating sections. The conveyor is configured to receive products from an upstream destination and discharge products to a downstream destination. A second conveyor, operable at a considerable slower speed than the first conveyor, is located in the same transverse plane as and is aligned adjacent to the first conveyor. Both conveyors travel in the same direction at the adjacent alignment. As products are discharged from the system, a wall of product is formed on the slower moving conveyor. As a result, products on the inner lane of the faster moving conveyor which would otherwise tend to move inward towards the discharge point, causing product turbulence and disruption, are urged back onto the inner lane by the product wall and then smoothly discharged from the system to the downstream destination. The use of this slower conveyor increases product stability by substantially eliminating product turbulence caused by the product bunching and nesting which normally occurs at the product discharge point. A substantially increased rate of product outfeed results.

Description

BACKGROUND OF THE INVENTION[0001]Product accumulation systems are routinely used in conjunction with conveyors for the storage and accumulation of products which are fed from upstream sources onto conveyors. In the normal operation of a typical system, products are placed on a conveyor at the upstream location, for instance at one operational station, and then transported to a downstream location by a conveyor where the next step in the manufacture or distribution of the products is to be accomplished. When there is a disruption at a downstream location which prevents the downstream destination from accepting products, system products which would normally be transported to the area of the disruption can be received and temporarily stored by an accumulator which is integral to the system. Examples of effective product conveyor and accumulation systems are disclosed in U.S. Pat. Nos. 6,575,287 and 6,959,802.[0002]As products with particular configurations, e.g. elongated bottles, circ...

AI Technical Summary

Benefits of technology

"The present invention is a product conveying and accumulation system and method that improves product stability and smooth outfeed at the system's discharge. It uses a primary conveyor with accumulation and re-circulating sections, and a separate conveyor section or lane that is stationary or operable at a slower speed than the primary conveyor to improve product stability, eliminate disruptions, and obtain smooth and increased product outfeed. The slower conveyor helps to position products in a temporary wall, which prevents them from moving inward towards the discharge point and causing product turbulence. The use of a separate conveyor section or lane increases the rate of product outfeed. The invention is designed to overcome the disadvantages and limitations of prior product conveying and accumulation systems."

Problems solved by technology

As products with particular configurations, e.g. elongated bottles, circulate around such conveyor / accumulation systems and other conveyor systems where some products are discharged downstream while others remain in the system, they are subject to product disruptions within the system.

These disruptions especially occur just prior to product discharge downstream.

Discharge disruptions primarily involve the bunching and nesting of products, which result in product instability and fallen and misaligned products.

As additional products enter the system from the upstream destination, they push the nested products which are ahead of them, causing product instability and exacerbating what may already be a clogged outfeed.

These problems are especially troublesome and are, in fact, exacerbated when the system is started up following a shutdown to address a downstream condition.

However, upon start-up, when the gate is opened and the system is returned to its product delivery mode, the immediate rapid influx of products at the discharge location results in increased nesting, bunching, and product turbulence, which, once again, creates the real threat of disruption of product flow.

While the systems in the U.S. Pat. Nos. 6,575,287 and 6,959,802 evidence significant, novel and effective systems in the conveying and accumulation of products, the systems disclosed and discussed therein do not specifically address the above stated problems of product instability at outfeed locations, under varying operating conditions.

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