Apparatus and method for dynamically controlling the spacing of conveyed objects

Abstract

A conveyor system (100) employs an independently controlled baffle (160). The baffle is controlled separately from the conveying surface using a linear conveyor system. The linear conveyor system allows the position of the baffle to be controlled based on parameters such as the length of the object being conveyed. The baffle is pivotally mounted to a mover of the linear conveyor system and is pivotable relative to the conveying surface to allow the baffle to fit into the space between the end of the conveyor lane and the container.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 049,790, filed on July 9, 2020, entitled “Apparatus and Methods for Dynamically Controlling the Spacing of Conveyed Objects,” the contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to the field of powered conveyors. More particularly, the present invention relates to systems and methods for dynamically controlling the spacing of conveyed objects. Background Art

[0004] It is often desirable to space conveyed objects in a selected manner along the direction of travel of a conveyor (e.g., a conveyor belt). This spacing enables downstream processing, such as sorting by diverting selected objects onto an outgoing conveyor. For example, it may be desirable to place only one package at a time on a section of a conveyor system (e.g., a diverter). If the packages are of different sizes, such as is often the case in the shipping industry, the spacing of the packages should be different to ensure that only one package is on a selected section at a time, while maintaining the smallest possible gap between packages. In addition, irregular packages (e.g., envelopes and bags) may be difficult for flights used to space the conveyed objects. Summary of the Invention

[0005] The conveyor system utilizes dynamically assignable baffles that are controlled separately from the conveying surface. The conveyor system includes a dynamic gap conveyor for spacing conveyed objects in a selected manner. The dynamic gap conveyor uses baffles that are independently driven by a linear conveyor system to control the spacing between conveyed objects.

[0006] According to one aspect, a dynamic gap conveyor includes: a frame forming a conveying path of a conveying surface; a conveying surface extending from a first end to a second end in a conveying direction and laterally extending from a first side edge to a second side edge; a linear conveying system; and a baffle extending laterally across the conveying surface. The linear conveying system includes an annular rail extending along a first side edge of the conveying surface and a plurality of movers. The annular rail accommodates a plurality of inducers that interact with the movers to move the movers along the annular rail. The baffle has a first end connected to the mover on a first side of the conveying surface.

[0007] According to another aspect, a baffle for a conveyor includes: a baffle body rotatably mounted on a mounting rod; a mounting assembly that receives the mounting rod to pivotally mount the baffle body to a mover of a linear conveying system; and a pivot mechanism for selectively pivoting the baffle body relative to the mover.

[0008] According to another aspect, a baffle for a conveyor includes a tubular base for pivotally receiving a mounting rod; a tapered body portion extending from the base and having a front surface and a rear surface; and a curved tip extending from the rear surface, the curved tip including an opening in a terminal edge to form a finger. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is an isometric view of a conveyor system including dynamically assignable baffles according to an embodiment of the present invention;

[0010] Figure 2 yes Figure 1 A side view of a conveyor system;

[0011] Figure 3 yes Figure 1 an isometric view of a portion of a conveyor system showing a baffle relative to a conveying surface;

[0012] Figure 4 yes Figure 3 a side view of a portion of;

[0013] Figure 5 yes Figure 3 A front view of a portion of;

[0014] Figure 6 is an isometric view of a baffle and connected mover of a conveyor system of an embodiment of the present invention;

[0015] Figure 7 is a side view of a baffle according to an embodiment of the present invention;

[0016] Figure 8 is an isometric view of a baffle according to an embodiment of the present invention;

[0017] Figure 9 is an isometric view of a baffle in a pivoted position at the end of a conveyor lane according to an embodiment of the present invention;

[0018] Figure 10 yes Figure 8 A bottom view of the baffle;

[0019] Figure 11 is an isometric view of a pivot mechanism of a dynamically assignable baffle according to an embodiment of the present invention;

[0020] Figure 12 is an isometric view of a baffle entering a curved portion of a guide rail in a conveyor frame according to an embodiment of the present invention;

[0021] Figure 13 yes Figure 1 A cross-sectional side view of the conveyor system near the end of the conveyor lane;

[0022] Figure 14 yes Figure 1 A detailed cross-sectional side view of the conveyor system near the end of the conveyor lane;

[0023] Figure 15 is an isometric view of an outer portion of a baffle and a conveyor guide rail that is dynamically assignable as the guide rail pushes the baffle into an active position at the beginning of a conveyor lane, in accordance with an embodiment of the present invention;

[0024] Figure 16 is an exploded view of a dynamically assignable baffle according to another embodiment; and

[0025] Figure 17 is an isometric view of a baffle body according to another embodiment. DETAILED DESCRIPTION

[0026] The conveyor system includes a dynamic gap conveyor to dynamically control the spacing between objects being transported through the conveyor system. The dynamic gap conveyor uses independently driven baffles to control the spacing between conveyed objects. The present invention will be described below with respect to certain illustrative embodiments. Those skilled in the art will appreciate that the present invention can be implemented in a variety of different applications and embodiments and is not specifically limited to its application in the particular embodiment depicted.

[0027] Figure 1 and 2 A dynamic gap conveyor system 100 is shown, comprising a frame 110 extending from a first end 111 to a second end 112 and forming a conveyor path for a conveyor 120 to move objects from the first end 111 to the second end 112. The illustrative system 100 includes two side-by-side conveyor belts 120, but may also include a single or more conveyor belts. A dynamic gap system 130 runs parallel to each conveyor 120 and includes independent baffles 160 for separating objects conveyed by the conveyors. For example, the dynamic gap system 130 can control and maintain consistent gaps between packages of different sizes to increase throughput. The dynamic gap system 130 includes a linear conveyor system connected to a plurality of baffles 160 that extend laterally above a conveyor conveying surface 122. The illustrative baffles 160 are controlled independently of the conveying surface 122.

[0028] The illustrative conveyor 120 comprises an endless conveyor belt 120 that loops around guides at each end 111, 112 of the frame, defining a top conveying surface 122 and forming a return path below the conveyor path to complete the loop. A drive (e.g., a motor-driven sprocket) moves the conveyor belt 120 in a loop to move objects from the first end 111 of the frame 110 to the second end 112. The illustrative system includes two side-by-side endless conveyor belts, but the invention is not limited thereto. Each conveyor path extends longitudinally from a first end 111 (which is the receiving end) to a second end 112 (which is the discharging end) and has a lateral width from a first side edge to a second side edge.

[0029] The present invention is not limited to conveyor belts for conveying objects, and any suitable means for conveying objects may be used.

[0030] The dynamic gap system 130 includes a plurality of baffles 160 extending transversely across the width or a portion of the width of the conveying surface 122 for guiding conveyed objects, the width being perpendicular to the conveying direction 12. The baffles 160 act as stops that limit the travel of objects (e.g., packages) to control their relative spacing on the conveying surface.

[0031] In an illustrative embodiment of the present invention, the baffles 160 are driven independently of the conveying surface 122, and in some embodiments, independently of each other. The baffles 160 can be separated by variable spacing distances, which allows the object spacing to be independently varied using the baffles 160. The position of the baffles 160 can be longitudinally adjustable relative to the conveying surface 122, and / or each baffle 160 can travel at a different speed than the conveying surface 122.

[0032] In one embodiment, the baffle 160 is driven by a linear transport system comprising a plurality of movers 133 connected to the baffle 160 and motor modules for propelling the movers, wherein each mover is independently controlled. Figure 2 As shown, each motor module includes an oblong circular rail 132 on each side of the conveyor that generally matches and abuts the path of the conveyor 120, although the invention is not limited thereto. Alternatively, the rail 132 may return along a different path, such as above or outside the conveyor. The illustrative rail 132 includes an inducer, such as an embedded electromagnetic coil or other element, which cooperates with an element, such as a magnetic plate, in the mover 133 to propel the mover at a controlled, variable pace through the loop formed by the rail 132. Suitable linear conveyor systems are available from Rockwell Automation ( Intelligent Track Systems), Beckhoff Automation LLC of Savage, MN, USA, B&R Automation of Eggelsberg, Austria, FESTO Corporation of Germany, and other linear conveyor system suppliers known in the art.

[0033] refer to Figure 3-5 , each illustrative baffle 160 includes a body portion 161 and a mounting portion 162, wherein the mounting portion 162 connects the body portion 161 to the mover 133 of the linear conveyor system so that as the mover 133 travels along the rail 132, the connected body portion 161 also moves, thereby making the baffle dynamically assignable across the conveying surface 122. The mounting portion 162 is configured to place the body portion 161 in a selected orientation above the conveying surface 122 of the associated conveyor belt 120 or other conveying surface to stop forwardly moving objects. Alternatively, the body portion 161 can push objects on the conveying surface forward or backward. In one embodiment, the body portion 161 is pivotally mounted to the mover 133 to allow the body portion 161 to pivot relative to the mover 133 and the conveying surface 122, as described below.

[0034] The illustrative conveying surface 122 includes a plurality of rollers 124, and the main body 161 of the baffle 160 is configured to accommodate the rollers 124. The rollers 124 have axes that are perpendicular to the direction of travel 12 of the dynamic gap conveyor 100. In the illustrative embodiment, the rollers 124 are arranged in longitudinal rows in a pattern that extends transversely across the width of the conveyor belt 120, but the present invention is not limited to this and the rollers 124 may have any suitable pattern. Additionally, the present invention is not limited to conveyors comprising conveyor belts having rollers embedded therein, but rather may encompass conveyors comprising powered rollers, wherein the rollers are connected to a chain at each end, or any suitable conveyor known in the art. The present invention is also not limited to conveying surfaces formed by rollers. For example, the conveying surface may include a material that allows objects to slide across the conveying surface, wherein the baffle 160 enables adjustment of the position of the objects on the conveying surface 122.

[0035] The rollers 124 can be activated by any suitable means to propel the conveyed objects forward at a speed faster than the speed of the conveyor belt 120, wherein the baffles form stops that selectively space and / or gap the objects relative to each other along the conveyor path. The baffles 160 are optionally used to achieve consistent spacing between conveyed objects regardless of the varying lengths of the conveyed objects. An example of a suitable conveyor belt having rollers is an activated roller belt available from Intralox, LLC of Harahan, Louisiana, USA. TM Activated Roller Belt TM A conveyor belt is available from Intralox, LLC, of ​​Harahan, LA), but other suitable conveyor belts may be used.

[0036] Also refer to Figure 6-8 , the body portion 161 of the baffle includes a base 163 configured to receive a mounting rod 164, a tapered body portion 165 having a front surface 169 and a rear surface 168, and a curved tip 166 that curves away from the distal end of the rear surface 168. The illustrative base 163 is configured to rotate about the mounting rod 164, as described below, but alternatively, the base may be fixed relative to the mounting rod 164. The illustrative mounting rod 164 comprises a carbon fiber tube or rod, but the invention is not limited thereto. The illustrative baffle 160 further includes end caps 158, but the invention is not limited thereto. The body portion 161 is sufficiently strong to withstand impact forces from conveyed objects. A plurality of openings 167 in the terminal edge of the curved tip 166 accommodate rollers 124 in the conveyor. The main body portion 161 is sized and configured so that the solid fingers 265 between the openings 167 of the curved portion 166 fit into the non-roller portion of the conveying surface 122 between the rollers 124 and lie directly above or in slight contact with the non-roller portion. The curved fingers 265 of the tip 166 preferably reach below the rollers on which the package rests and are thus below the leading edge of the conveyed package. In the conveyor lane, the mounting portion 162 is placed in an active position, thereby placing the main body portion 161 at an angle relative to the conveying surface, such as Figure 3 、 48 . In one embodiment, the body portion 161 is angled forward such that the rear surface 168 extends at an angle Ω between about 1° and about 15°, and preferably between about 5° and about 10°, relative to vertical, and ends at a curved tip 166, thereby forming a scoop-like structure, although the invention is not limited thereto. Alternatively, the baffle body 161 may be vertical or angled rearward to facilitate pushing conveyed objects. The illustrative geometry prevents plastic bags or small envelopes pushed forward into the baffle from becoming stuck between the baffle and the conveyor belt by slightly lifting the pushed packages upward, but the angle and specific geometry of the baffle may vary depending on the products being conveyed.

[0037] The body portion 161 of the baffle can be formed from any suitable material using any suitable process to produce a durable and lightweight structure. For example, the body portion 161 can be 3-D printed using plastic. Examples of suitable plastics include nylon, nylon mixed with chopped carbon fiber, polypropylene, acrylonitrile butadiene styrene (ABS), and other materials known in the art. The body portion 161 can alternatively be injection or compression molded, machined, or formed using any other suitable manufacturing process.

[0038] The illustrative main body member 161 is pivotally connected to the mover 133 via a mounting portion 162 to allow the main body member 161 to pivot or otherwise shift relative to the conveying surface 122. For example, the main body member 161 can be pivoted at the end 112 of the conveying lane to allow the baffle 160 to fit into the space between the end 112 of the conveying lane and a receiving conveyor or other receiving container. In one embodiment, a cam can be used to selectively pivot the main body member 161, although other suitable mechanisms for selectively pivoting the main body member 161 can also be used.

[0039] refer to Figure 8-10The mounting portion 162 includes a base plate 171 for mounting the baffle assembly 160 to the mover 133 using fasteners 172 inserted through aligned openings or another suitable fastening mechanism. A sheath 174, which may be formed from bent sheet metal, forms a housing that covers and connects the components of the mounting portion 162. At a first end, the sheath 174 receives a mounting base 180 and is secured to the mounting base 180 using fasteners 181. The mounting base 180 is connected to the baffle body. The mounting base 180 acts as an adapter for the baffle body 161, allowing the sheath 174 to be connected to the baffle body 161. The illustrative mounting base 180 includes an opening that forms a bearing that allows the mounting rod 164 to extend therethrough without interference. The mounting base 180 includes a shaped protrusion (not shown) that is received in a recess in the edge of the baffle body to secure the mounting base 180 to the baffle body, such that rotation of the sheath 174 causes rotation of the baffle body 161. Any suitable means for securing the boot 174 to the baffle body 161 may be used.

[0040] The illustrative mounting rod 164 passes through the mounting base 180 and into the housing 174. Within the housing, the mounting rod 164 is received in a shaft clamp 177, which is coupled to the base plate 171 using fasteners 178 and holds the mounting rod 164 in place. The mounting rod 164 can be fixed relative to the base plate 171, wherein the tapered body 165 can rotate about the mounting rod 164, or the mounting rod 164 can rotate within an opening in the shaft clamp 177, such that the tapered body portion 165 of the baffle can rotate relative to the base plate 171.

[0041] At a second end, the illustrative sheath 174 houses a pivot mechanism 182 for selectively pivoting the sheath 174 and the connected tapered body portion 165 relative to the mover 133. Figure 11An embodiment of the pivot mechanism 182 is shown in detail in FIG. The pivot mechanism 182 includes a base 183 that is housed within the second end of the sheath 174 and coupled thereto using a fastener 179. A crank arm 176 at the outer end of the base 183 is connected to a cam follower 175 that is offset from the pivot mechanism base 183 and includes a cylindrical protrusion, although the invention is not limited thereto. The pivot mechanism base 183 can be a generally cylindrical structure configured to clamp onto a cam shaft 185 that extends through an opening 187 in the crank arm 176, through the base 183, and through a bearing support 186 that extends upward from the base plate 171. The illustrative crank arm 176 includes two segments that enclose and are clamped using a fastener to form the cam shaft opening 187, although the invention is not limited thereto. The distal end of the cam shaft 185 extends through the bearing support 186 and is coupled to a torsion spring 192 or other biasing mechanism for biasing the flapper body 161 to a default position. The illustrative torsion spring 192 biases the flapper body to a generally horizontal position as the flapper 160 travels along the conveyor's return path beneath the conveyor.

[0042] The illustrative mounting portion 162 of the flapper 160 may additionally include a protrusion 194 extending from the base plate 171 just below the edge of the sheath 174. The protrusion 194 forms a mechanical end stop that prevents the flapper 160 from over-rotating.

[0043] like Figure 9 and 12 As shown in FIG, the conveyor frame 110 includes a guide rail 117 configured to receive a cam follower 175. The cam follower 175 engages the guide rail 117 of the frame to control the rotational position of the baffle body 161. The guide rail 117 can be raised at the end of the conveyor path, thereby raising the cam follower 175 and causing the guard 174 and the connected tapered portion of the baffle body 165 to rotate relative to the base plate 171 and the attached mover 133, as shown in FIG. Figure 12 As shown in .

[0044] refer to Figure 13 and 14As the dynamically assignable baffles 160 approach the end 112 of the conveyor lane, the guide rails 117 bend to reduce the distance between the guide rails and the engaged cam followers 175 and the conveyor surface 122. As shown, the frame's side rails 118 also taper toward the end of the lane. Prior to bending, the guide rails 117 hold the baffles 160a, 160b in an active conveying position, as described above, along the conveyor belt's direction of travel 12. During the bend, the guide rails 117 cause the cam followers 175 to move upward relative to the base plate 171, causing the baffles 160c, 160d to rotate and push their baffle bodies 165 into an inactive position generally parallel to the base plate 171, thereby allowing the baffles to be placed into the space between the end 112 of the lane and the output conveyor 210 or other receptacle for conveyed objects. The baffle may be held in an inactive position by a return path of the rail, which in the illustrated embodiment is below the conveyor path, although the invention is not so limited.

[0045] like Figure 15 As shown in FIG, the guide rail 117 can push the baffle 160 into the active position at the beginning of the conveyor path by moving the cam follower 175 downwardly relative to the base plate 171 to rotate the mounting portion and attached main body portion downwardly about the cam shaft and mounting rod and into the active position.

[0046] refer to Figure 16 In another embodiment, a dynamically adjustable baffle 260 for a conveyor includes a body portion 261 and a mounting portion 262 that connects the body portion 261 to a mover of a linear transport system. The illustrative body portion 261 is similar to the body portion 161 described above.

[0047] Mounting portion 262 includes a base plate 271 for mounting baffle assembly 260 to the mover using fasteners inserted through aligned openings or another suitable fastening mechanism, as described above. A sheath 274, formed from a bent sheet of metal, forms a housing that covers the mounting portion 262 and connects the assembly to the baffle body 261. At a first end, baffle body 261 is secured to sheath 274 via a cylindrical protrusion 298 extending from the baffle body and a cylindrical adapter 299, which receives a fastener 281 extending through an opening in sheath 274. At a second end, sheath 274 is connected to cam assembly 280 via fastener 279. A mounting rod 264 extends through the base of baffle portion 261, protrusion 298, and adapter 299, and is located between sheath 274 and base plate 271. Mounting rod 264 is rotatably received at its second end in an opening in cam assembly 280 using a bearing or other suitable mechanism. A clamp 286 covers mounting rod 264 and is connected to base plate 271 via fasteners 287 to prevent interference with rotatable sheath 274. A mounting rod bracket 288 receives mounting rod 264 and controls its position. The illustrative mounting rod 264 further includes a covering 291 made of polyurethane or another suitable material to evenly distribute force across the mounting rod, thereby promoting smooth operation and dampening vibrations, but the invention is not limited thereto.

[0048] A torsion spring 292, wound around the mounting rod 264 and having legs extending between the sheath 274 and the base plate 271, biases the baffle body to a default position. The illustrative torsion spring 292 biases the baffle body to a generally horizontal position as the baffle travels along the return path of the conveyor belt beneath the conveyor path. Other suitable biasing mechanisms may be used.

[0049] The illustrative cam assembly 280 includes a body including a base 282 that rotatably receives the mounting rod 264. A crank arm 276 at the outer end of the base 286 is connected to a rotatable cam follower 275 that is offset from the base and includes a cylindrical protrusion that is rotatable relative to the base to prevent or reduce wear, although the invention is not limited in this regard.

[0050] When the cam follower 275 is induced to move upward or downward via the rails or other guides, the attached sheath 274 and baffle body 261 rotate about the mounting rod 264 as described above.

[0051] Figure 17Another embodiment is shown in which the baffle body 361 includes an integral adapter 399 for connecting the baffle body to the sheath or other means for pivotally mounting the baffle to the mover. The adapter 399 extends from a base 363 that receives a mounting rod. The adapter 399 has an outer surface that is configured to be received in an associated sheath, as described above, and includes an opening 398 for receiving a fastener. An outer surface protrusion 392 forms a stop for the sheath. An internal opening 364 rotatably receives the mounting rod. The baffle body 361 further includes a tapered body portion 365 having curved tips 366 that form spaced-apart fingers 365, as described above.

[0052] Any suitable means for pivotally connecting the baffle body to the mover may be used, and the present invention is not limited to the configuration described above. For example, the cam portion may be located in a different position or have a different configuration. A motor, magnet, or other inducer may also be used to pivot the baffle body to allow the baffle to be assembled between the conveyor's feed section and the container. Other variations are possible without departing from the scope of the present invention.

[0053] The present invention has been described with respect to certain illustrative embodiments. Those skilled in the art will appreciate that the present invention can be implemented in a number of different applications and embodiments and is not specifically limited to its application in the particular embodiments depicted.

Claims

1. A dynamic gap conveyor comprising: a frame forming a conveying lane of the conveying surface; a conveying surface extending in a conveying direction from a first end to a second end and laterally from a first side edge to a second side edge; a linear conveyor system comprising an annular rail extending along a first side edge of the conveying surface and a plurality of movers, the annular rail housing a plurality of inducers that interact with the plurality of movers to move the plurality of movers along the annular rail, wherein the plurality of movers includes a first mover; and a baffle extending transversely across the conveying surface, the baffle having a first end connected to the first mover on a first side of the conveying surface; wherein the baffle includes a main body portion including a base mounted to the mounting rod and a body extending from the base; wherein the body comprises a front surface, a rear surface, and a curved tip extending away from the rear surface; wherein the conveying surface comprises a plurality of rollers having axes perpendicular to the conveying direction; and The curved tip of the body includes a plurality of openings to form fingers that fit between the rollers on the conveying surface.

2. The dynamic gap conveyor of claim 1, wherein the baffle is pivotally connected to the first mover.

3. The dynamic gap conveyor of claim 2, further comprising a pivot mechanism for pivoting the barrier relative to the first mover.

4. The dynamic gap conveyor of claim 1 , wherein the baffle further comprises: a mounting portion for pivotally connecting the main body portion to the first mover; Wherein, the main body is a conical body.

5. The dynamic gap conveyor according to claim 4, wherein the mounting portion includes a sleeve, a base plate and a shaft clamp, the sleeve connecting the main body portion to a cam to achieve rotation of the sleeve and the main body portion, the base plate being fastened to the first mover, and the shaft clamp being fastened to the base plate for receiving the mounting rod.

6. The dynamic gap conveyor of claim 5, further comprising: a crank arm connected to a distal end of the sheath; and A cam follower extends from the crank arm and is offset from the mounting rod.

7. The dynamic gap conveyor of claim 6, wherein the frame includes a guide rail for engaging the cam follower.

8. The dynamic gap conveyor of claim 7, wherein the guide rail curves near an end of the conveyor path to pivot the baffle about the mounting rod.

9. The dynamic gap conveyor of claim 5, further comprising a torsion spring mounted to an end of the mounting rod within the guard for biasing the guard into a default position.

10. The dynamic gap conveyor of claim 4, wherein the mounting portion places the rear surface of the body at a non-perpendicular angle relative to the conveying surface when the baffle is positioned over the conveying lane.

11. The dynamic gap conveyor of claim 10, wherein the rear surface extends at an angle Ω between about 5° and about 10° relative to the conveying surface, the trailing end being the curved tip, thereby forming a scoop-like structure above the conveying surface.

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