Conveyor with guide rails for supporting a steering unit

Abstract

The present invention is entitled "Conveyor with Guide Rails for Supporting a Turn Unit." The present invention describes a conveyor that includes a conveyor frame, a first guide rail assembly, a turn unit having a switching assembly, and an alignment key. In this regard, the first guide rail assembly is positioned on a first portion of the conveyor frame such that a guide rail of the first guide rail assembly extends along a length of the conveyor. In some examples, the first guide rail includes a first guide rail and a second guide rail positioned parallel to the first guide rail. Additionally, the first guide rail defines a groove along a length of the first guide rail assembly. Moreover, according to some examples, the switching assembly defines a key slot. The key slot is adapted to enable the alignment key to pass through the key slot and further into the groove of the first guide rail, thereby aligning the switching assembly on the first guide rail.

Description

[0001] This application is a divisional application of Chinese patent application No. 202011081604.5, filed on October 10, 2020, entitled "Transmitter with Guide Rails for Supporting Steering Unit". Technical Field

[0002] The exemplary embodiments described herein relate generally to conveyors for turning articles from a sorting conveyor to a turning position, and more specifically, to conveyors having guide rails for supporting turning units. Background Technology

[0003] Generally speaking, in material handling environments such as, but not limited to, distribution centers, warehouses, storage or shipping centers, material handling systems can convey, handle, sort and organize various types of products (e.g., items, cartons, boxes, containers, shipping containers, bags, packaging, etc.) at high speeds on conveyors. Summary of the Invention

[0004] A brief summary of the invention is provided below to offer a basic understanding of some aspects of the disclosed material handling system. This summary is not an exhaustive overview and is neither intended to identify key or critical elements nor to describe the scope of such elements. Its purpose is to serve as an introduction to the detailed embodiments provided below, to present some concepts of the described features in a simplified form.

[0005] The various exemplary embodiments described herein relate to a conveyor and a steering unit for the conveyor. The conveyor may include a conveyor frame, a first rail assembly, an alignment key, and a steering unit. In some examples, the first rail assembly may be configured to be positioned on a first portion of the conveyor frame such that the rails of the first rail assembly extend along the length of the conveyor. Additionally, according to some examples, the first rail assembly may include: (i) a first rail that defines a groove along the length of the first rail assembly; and (ii) a second rail that is positioned parallel to the first rail. Furthermore, according to some exemplary embodiments, the steering unit may include a switching component that defines a keyway. The keyway may be adapted to allow the alignment key to pass through the keyway into the groove of the first rail, thereby aligning the switching component on the first rail.

[0006] According to some exemplary embodiments, an alignment key for aligning a switching assembly on a first guide rail may include: (i) a top portion; (ii) a bottom portion extending from the top portion; and (iii) a hook defined between the top and bottom portions. In this regard, in some exemplary embodiments, the hook defined on the alignment key may be adapted to engage with a surface of the switching assembly when the alignment key is inserted into a keyway.

[0007] In some exemplary embodiments, the hook may include a cantilever portion that is adapted to snap into a groove through a keyway, thereby abutting the surface of the switching component.

[0008] According to some exemplary embodiments, the steering unit of the conveyor may include: (i) a steering track that can be positioned downstream of the switching component; and (ii) an end plate that can be positioned downstream of the steering track.

[0009] In some exemplary embodiments, the conveyor may further include a second guide rail assembly configured to be positioned on a second portion of the conveyor frame along the conveying direction of the conveyor. In this regard, the second guide rail assembly may include a third guide rail and a fourth guide rail, respectively. For this purpose, the fourth guide rail may be positioned parallel to the third guide rail. Additionally, according to an exemplary embodiment, the end plate of the steering unit may be configured to be mounted on the third and fourth guide rails of the second guide rail assembly.

[0010] According to some exemplary embodiments, the switching assembly may include at least one of the following: a switching plate, a bridging plate, and a steering plate. In this regard, in some examples, each of the switching plate, bridging plate, and steering plate may include a corresponding keyway adapted to receive a corresponding alignment key passing through the top or bottom surface of the corresponding plate.

[0011] In some exemplary embodiments, the switching assembly may include a first plate and a second plate. The first plate and the second plate may be mounted on a first guide rail assembly. In this regard, the second plate may be aligned with the first plate based on a first alignment key and a second alignment key respectively engaging through keyways defined on the first plate and a groove defined in a guide rail defined on the first guide rail assembly.

[0012] According to some exemplary embodiments, the switching assembly can be bolted to the first guide rail assembly, the bolt passing through a hole defined on the switching assembly and entering a recess. Additionally, a nut can be fastened over the bolt, thereby securing the switching assembly to the first guide rail assembly.

[0013] According to some exemplary embodiments, the switching assembly may include a switching plate, which may include a first keyway adapted to allow a first alignment key to pass through the first keyway and enter a groove in a first guide rail, thereby aligning the switching plate on the first guide rail. Additionally, the switching assembly may include a steering plate. The steering plate may include a second keyway adapted to allow a second alignment key to pass through the second keyway and enter a groove in the first guide rail, thereby aligning the steering plate on the first guide rail. Furthermore, the switching assembly may include a bridge plate positioned between the switching plate and the steering plate. In this regard, the bridge plate may include a third keyway adapted to allow a third alignment key to pass through the third keyway and enter a groove in the first guide rail, thereby aligning the bridge plate on the first guide rail.

[0014] According to some exemplary embodiments, the second guide rail may include a top portion and a bottom portion. In this regard, the top portion may define a groove adapted to receive a chain track of a conveyor. Additionally, the bottom portion may define a longitudinal groove adapted to receive a second side portion of a switching assembly.

[0015] In some exemplary embodiments, the switching component may be configured to be mounted on the first guide rail assembly based on a second side of the switching component to be positioned within a longitudinal groove of the second guide rail and an alignment key to pass through a keyway on the second side of the switching component into the groove.

[0016] In some exemplary embodiments, the switching component may be configured to be slidably movable along the length of the first guide rail assembly. In this respect, a second side of the switching component moves within a longitudinal groove of the second guide rail, and a first side of the switching component moves above the first guide rail.

[0017] In some exemplary embodiments, the steering unit may be slidably moved along the length of the conveyor on a first guide rail assembly and a second guide rail assembly.

[0018] Some exemplary embodiments described herein relate to a steering unit of a sorting conveyor. The steering unit of the sorting conveyor may include a first guide rail assembly. The first guide rail assembly may be configured to be positioned on a first portion of the conveyor frame of the sorting conveyor such that the guide rails of the first guide rail assembly extend along the length of the sorting conveyor. In this regard, the first guide rail assembly may include: (i) a first guide rail that may define a groove along the length of the first guide rail assembly; and (ii) a second guide rail that may be positioned parallel to the first guide rail. Additionally, the steering unit of the sorting conveyor may include a switching assembly. The switching assembly may include a switching plate that may define a keyway. The keyway may be adapted to allow an alignment key to pass through the keyway into the groove of the first guide rail, thereby aligning the switching assembly on the first guide rail.

[0019] In some exemplary embodiments, the second guide rail of the steering unit may include a top portion and a bottom portion. In this regard, the top portion may define a groove adapted to receive a chain track of a sorting conveyor. Additionally, the bottom portion of the steering unit may define a longitudinal groove adapted to receive a second side portion of the switching assembly.

[0020] According to some exemplary embodiments, the switching component of the steering unit can be configured to slide along the length of the first guide rail assembly, such that the side of the switching component moves within a longitudinal groove of the second guide rail.

[0021] According to some exemplary embodiments, the steering unit may include a steering rail and an end plate. In this respect, the steering rail may be located downstream of the switching assembly, and the end plate may be located downstream of the steering rail.

[0022] According to some exemplary embodiments, the steering unit may further include a second guide rail assembly. The second guide rail assembly may be configured to be positioned on a second portion of the conveyor frame along the conveying direction of the sorting conveyor. In this regard, the second guide rail assembly may include a third guide rail and a fourth guide rail, the fourth guide rail being positioned parallel to the third guide rail. According to an exemplary embodiment, the end plate of the steering unit may be configured to be mounted above the third and fourth guide rails of the second guide rail assembly.

[0023] Some exemplary embodiments described herein relate to a sorting conveyor for turning articles to a turning position. The sorting conveyor may include a conveyor frame having a first side frame, a second side frame, and a bottom frame. The bottom frame may be mounted between the first and second side frames. In some exemplary embodiments, the sorting conveyor may also include a guide rail assembly. In this regard, the guide rail assembly may extend along the length of the sorting conveyor from one end of the conveyor frame to a second end of the conveyor frame and is adapted to be mounted on a portion of the bottom frame. The guide rail assembly may include: a first guide rail defining a groove along the length of the first guide rail assembly; and a second guide rail positioned parallel to the first guide rail. Additionally, the guide rail assembly may include a switching assembly that is mounted between the first and second guide rails when an alignment key is inserted through a keyway defined on the switching assembly into the groove of the first guide rail.

[0024] The above description of the invention is provided merely to outline some exemplary embodiments to provide a basic understanding of some aspects of this disclosure. Therefore, it should be understood that the above embodiments are merely examples and should not be construed as limiting the scope or substance of this disclosure in any way. It should be understood that, in addition to those summarized herein, the scope of this disclosure covers many possible embodiments, some of which will be further described below. Attached Figure Description

[0025] The description of the exemplary embodiments can be read in conjunction with the accompanying drawings. It should be understood that, for simplicity and clarity of illustration, the elements shown in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements are exaggerated relative to others. Embodiments incorporating the teachings of this disclosure are shown and described with reference to the accompanying drawings, in which:

[0026] Figure 1 A perspective view of a conveyor according to some exemplary embodiments described herein is shown, the conveyor including multiple rails to support the installation of switching components.

[0027] Figure 2 A perspective view of a conveyor including multiple guide rails and a steering unit according to some exemplary embodiments described herein is shown, the steering unit including a switching component.

[0028] Figure 3 A top view of a steering unit according to some exemplary embodiments described herein is shown, the steering unit including a switching component mounted on a guide rail assembly of a conveyor.

[0029] Figure 4 A perspective view is shown of a switching assembly using multiple alignment keys mounted on a rail assembly according to some exemplary embodiments described herein.

[0030] Figure 5 A perspective view is shown of a switching assembly mounted between a first and a second guide rail of a guide rail assembly, according to some exemplary embodiments described herein.

[0031] Figure 6 A cross-sectional view is shown of a switching assembly using multiple alignment keys mounted on a guide rail assembly according to some exemplary embodiments described herein.

[0032] Figure 7 A perspective view of an alignment key and a keyway defined on a switching component according to some exemplary embodiments described herein is shown.

[0033] Figure 8 A cross-sectional view of a second guide rail with a defined longitudinal groove in a guide rail assembly according to some exemplary embodiments described herein is shown. Detailed Implementation

[0034] Some embodiments of this disclosure will be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of this disclosure. In fact, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to enable this disclosure to meet applicable legal requirements. Unless otherwise specified, the terms “or” and “optionally” are used herein in the sense of alternatives and combinations. The terms “illustrative” and “exemplary” are used for examples without an indication of quality level. Throughout the document, similar reference numerals refer to similar elements.

[0035] The components shown in the accompanying drawings represent components that may or may not be present in the various embodiments of this disclosure described herein, such that the embodiments may include fewer or more components than those shown in the drawings without departing from the scope of this disclosure.

[0036] Conveyors used in material handling environments include conveyor systems (e.g., but not limited to, roller conveyors, belt conveyors mounted between the sides of a conveyor frame, or conveyors defined by multiple slats mounted above the conveyor frame) for moving articles from one location to another. Some of these conveyors are sorting conveyors (e.g., but not limited to, slider sorters) configured to sort articles based on selectively turning them onto corresponding turning paths. Some of these slider-based sorting conveyors include conveyor systems defined by multiple slats configured to support lateral movement of pushers. In this respect, some slider sorting conveyors include a turning unit with a turning guide path and a switching assembly that can be mounted upstream of the turning guide path on the conveyor frame of the sorting conveyor. The switching assembly of such sorting conveyors includes a switching device movable between two positions (e.g., a first position or a second position) to selectively turn one or more pushers from their original path to the turning guide path of the turning unit. The steering guide path mentioned herein typically includes an arcuate section that provides a path for the pushing block's promotional movement. For this purpose, the pushing block, as it moves through the steering guide path, can gently contact the articles being conveyed on the conveyor bed, thereby guiding the articles toward the steering channel. An example of such a slider sorting conveyor is described in U.S. Patent Application No. US12 / 014,822, filed January 16, 2008, entitled "Sortation Conveyor".

[0037] Typically, mounting switching assemblies on the conveyor frame of a slider sorting conveyor presents associated challenges and limitations. For example, in some cases, the switching assembly may be mounted on a portion of the conveyor frame (e.g., a side frame or a cross brace of the conveyor frame). In such cases, mounting the switching assembly typically involves manually aligning one or more plates of the switching assembly at the desired location on the conveyor frame, which can be cumbersome and time-consuming. Furthermore, if the plates of the switching assembly are misaligned or incorrectly mounted on the conveyor frame, this can impede the movement of the pusher along the path defined by the switching assembly, and may even result in damage to the switching assembly, the pusher, and / or any other component of the sorting conveyor. Additionally, in some cases, it may be desirable to mount a steering unit (i.e., both the switching assembly and the steering guide path) on the conveyor frame such that the distal end of the steering path is aligned with a steering channel connected to the sorting conveyor. In such cases, to meet these installation requirements, mounting the switching assembly on the conveyor frame can sometimes be challenging due to interference between one or more components of the switching assembly and one or more cross braces of the conveyor frame. This often necessitates redesigning the switching assembly itself (e.g., switching plate or steering plate) or steering unit (i.e., both the switching assembly and the steering guide path) to meet the installation requirements of the customer's material handling site. Therefore, mounting the switching assembly on the conveyor frame presents associated challenges.

[0038] The various exemplary embodiments described herein relate to conveyors that facilitate the mounting of steering units on conveyor frames of conveyors. In this regard, according to some exemplary embodiments, the conveyor described herein includes a guide rail assembly with multiple guide rails supporting the mounting of one or more components of the steering unit (e.g., but not limited to, switching components, steering rails, etc.). That is, by implementing the various exemplary embodiments described herein, the mounting of the steering unit on the conveyor can be easily customized to meet the installation requirements of a customer's material handling environment. Additionally, some exemplary embodiments described herein also relate to an improved design of a switching component that can be mounted on a conveyor frame of a sorting conveyor. In this regard, the switching component is designed and configured such that (a) any interference between components of the switching component (e.g., actuator unit) and the cross braces of the conveyor frame is avoided, (b) one or more plates of the switching component can self-align during installation (e.g., mounting on the conveyor frame), and (c) the pusher is selectively deflected, thereby causing a desired impact (e.g., hard or soft contact) on the workpiece via the slider surface of the pusher.

[0039] According to some exemplary embodiments described herein, a "slider sorting conveyor" can refer to a conveyor that may include one or more pushers configured to travel laterally (i.e., laterally to the longitudinal direction of travel of the conveyor surface) to deflect articles carried by the conveyor surface to one or more deflection positions associated with the conveyor. In this regard, in some examples, the pushers may be guided along a deflection guide path to gently engage the conveyed articles laterally and gradually accelerate them to a deflection unit mechanically coupled to the conveyor.

[0040] Turning now to the accompanying drawings, the specific embodiments illustrated below, taken in conjunction with the drawings, are intended to describe various configurations and are not intended to represent the only configuration in which the concepts described herein can be practiced. The specific embodiments include detailed descriptions intended to provide a comprehensive understanding of the various concepts, wherein similar figures refer to similar parts throughout several views. However, it will be apparent to those skilled in the art that these concepts can be practiced without these specific details.

[0041] Figure 1 A perspective view 100 of a conveyor 102 in a material handling environment is shown. According to some exemplary embodiments, the conveyor 102 may correspond to a sorting conveyor, i.e., a conveyor configured for sorting one or more articles in a material handling environment. Inventively, the conveyor 102 may include a conveyor frame 104. The conveyor frame 104 may be defined by a first side frame 106, a second side frame 108, a member 109 connected to a bottom frame, and one or more cross braces 110-1, 110-2, 110-3, 110-4, 110-5...110-n. In this respect, the member 109 of the bottom frame may be mounted between the first side frame 106 and the second side frame 108. Additionally, as shown in the figure, the cross braces 110-1, 110-2, 110-3, 110-4, 110-5...110-n can be installed on the component 109 of the bottom frame between the first side frame 106 and the second side frame 108.

[0042] Additionally, according to some exemplary embodiments described herein, conveyor 102 may include one or more guide rail assemblies having guide rails, such as metal extrusions that may extend parallel to the length of conveyor 102. Exemplarily, conveyor 102 may include a first guide rail assembly 112 and a second guide rail assembly 114 that can be positioned on conveyor frame 104. The first guide rail assembly 112 may include a first guide rail 116 and a second guide rail 118. Additionally, the second guide rail assembly 114 may include a third guide rail 120 and a fourth guide rail 122. As shown, the second guide rail 118 may be positioned parallel to the first guide rail 116 on conveyor frame 104, and the fourth guide rail 122 may be positioned parallel to the third guide rail 120 on conveyor frame 104.

[0043] According to some exemplary embodiments, guide rail assemblies 112 and 114 may be positioned on a first portion of the conveyor frame 104 (e.g., on the cross brace 110) such that the guide rails (116 to 122) extend in the X direction along the length of the conveyor. In other words, in some exemplary embodiments, each of the first guide rail 116, the second guide rail 118, the third guide rail 120, and the fourth guide rail 122 may extend substantially parallel to the side frames 106 and 108 along the length of the conveyor 102.

[0044] According to some exemplary embodiments described herein, a plurality of guide rails of conveyor 102 (e.g., guide rails 116 to 122) may be configured to support the mounting of one or more components of a steering unit (not shown) for turning articles from conveyor 102. Furthermore, according to some exemplary embodiments, one or more cross braces 110 of conveyor frame 104 (e.g., first cross brace 110-1, second cross brace 110-2, third cross brace 110-3, fourth cross brace 110-4, fifth cross brace 110-5, etc.) may support the mounting of guide rail assemblies 112 and 114. (Refer to...) Figures 2 to 8 Further details about the guide rail assembly are described below.

[0045] Figure 2 A perspective view 200 of a conveyor 102 including multiple guide rails (116 to 122) and a deflection unit 202 is shown. According to some exemplary embodiments described herein, the deflection unit 202 may include a switching assembly 204. According to some exemplary embodiments, the deflection unit 202 may be configured to deflect one or more articles from the conveyor 102 to a deflection channel (not shown) associated with the conveyor 102. For this purpose, according to some exemplary embodiments, the deflection unit 202 may include at least three components: (i) the switching assembly 204, (ii) a deflection guide rail 206 positioned downstream of the switching assembly 204, and (iii) an end plate 208 positioned downstream of the deflection guide rail 206. According to various exemplary embodiments, the deflection unit 202 may be configured to cause movement of one or more pushers (not shown) of the conveyor 102 to deflect one or more articles on the sorting conveyor 102, details of which will be described below. For example, according to some exemplary embodiments, the steering unit 202 may cause the movement of one or more push blocks of the conveyor 102 according to some of the techniques described in the following U.S. patent application: U.S. patent application US12 / 014,822, entitled "Sortation Conveyor," filed January 16, 2008, details of which are incorporated herein by reference.

[0046] By way of example, according to the various exemplary embodiments described herein, the steering unit 202 may be mounted between two ends of the conveyor frame 104 (e.g., a first end 210 and a second end 212). In this regard, in some exemplary embodiments, the steering unit 202 may be positioned above the conveyor frame 104 such that the switching assembly 204 of the steering unit 202 is positioned on the first guide rail assembly 112, i.e., toward the first end 210, and the end plate 208 of the steering unit 202 is positioned on the second guide rail assembly 114, i.e., toward the second end 212. Thus, the steering guide rail 206 is positioned between the first guide rail assembly 112 and the second guide rail assembly 114. In other words, in some exemplary embodiments, when the steering unit 202 is placed on the conveyor frame 104, the steering guide rail 206 of the steering unit 20 connects the first guide rail assembly 112 to the second guide rail assembly 114 of the conveyor 102.

[0047] According to some exemplary embodiments, when the steering unit 202 is positioned on the conveyor frame 104, various components of the steering unit 202 can be mounted on the conveyor frame 104. For example, the switching assembly 204 of the steering unit 202 can be mounted on the first guide rail assembly 112, and the end plate 208 of the steering unit 202 can be mounted on the second guide rail assembly 114, thereby mounting the steering unit 202 on the conveyor frame 104. Figures 3 to 8 Further details are described in relation to the various components associated with the installation of the steering unit 202.

[0048] According to some exemplary embodiments, before the steering unit 202 is fixedly mounted on the conveyor frame 104, the steering unit 202 may engage with the guide rail assemblies 112 and 114 and may be slidably moved to a desired position along the length of the conveyor 102 (i.e., along the X direction). In other words, in some exemplary embodiments, the steering unit 202 may be moved in the X direction to adjust the position of the steering unit 202 relative to a steering channel / steering branch (not shown) connected to the sorting conveyor 102. For example, in some exemplary embodiments, the steering unit 202 may be slidably moved to a position on the guide rail assemblies 112 and 114 such that the distal end of the steering unit 202 (i.e., the end of the end plate 208) engages with the entrance portion of the steering channel (not shown) associated with the conveyor 102. In other words, the steering unit 202 is slidably movable along the length of the conveyor 102, can be positioned upstream of a steering channel (not shown), and can subsequently be fixedly mounted on guide rail assemblies 112 and 114 such that a portion of the steering unit 202 engages with the steering channel on the conveyor 102. Therefore, according to the various exemplary embodiments described herein, the movement of the steering unit 202 along the length of the conveyor 102 on the guide rail assemblies 112 and 114 adjusts the position of the switching assembly 204 and / or end plate 208 fixedly engaged on the conveyor frame 104. In this regard, it should be understood that the layout of the material handling environment in which the conveyor 102 is to be installed should also be considered in order to position the steering channel and the steering unit 202 on the conveyor 102.

[0049] According to some exemplary embodiments, the movement of the steering unit 202 to a desired position on the conveyor frame 104 can be achieved based on the slidable movement of the switching assembly 204 and the end plate 208 of the steering unit 202 within a groove defined by one or more guide rails (116 to 122) of the guide rail assemblies 112 and 114, the details of which will be referred to below. Figures 3 to 8 Describe it.

[0050] Figure 3 A top view 300 of a steering unit 202 according to some exemplary embodiments described herein is shown, the steering unit including a switching assembly 204 mounted on guide rail assemblies 112 and 114 of conveyor 102. Exemplarily, the steering unit 202 is mounted on conveyor frame 104. In this respect, as shown, the switching assembly 204 may be configured to be mounted above the guide rails of the first guide rail assembly 112 (i.e., the first guide rail 116 and the second guide rail 118). Additionally, in some exemplary embodiments, the end plate 208 of the steering unit 202 may be configured to be mounted on the guide rails of the second guide rail assembly 114 (i.e., the third guide rail 120 and the fourth guide rail 122). Thus, a steering guide rail 206 may be positioned on the conveyor frame 104 between guide rail assemblies 112 and 114.

[0051] According to some exemplary embodiments, the switching assembly 204 of the steering unit 202 may include (i) a switching plate 302, (ii) a bridging plate 304, and (iii) a steering plate 306. As shown, the bridging plate 304 may be positioned between the switching plate 302 and the steering plate 306. For this purpose, the bridging plate 304 may be placed between the switching plate 302 and the steering plate 306 and above the rails 116 and 118, such that one or more paths defined by the switching plate 302 and the steering plate 306, respectively, engage through the path defined by the bridging plate 304 for movement of the push block. In some exemplary embodiments, the switching assembly may include two plates, namely a first plate and a second plate (e.g., the switching plate 302 and the steering plate 306), and may not include the bridging plate. According to the various exemplary embodiments described herein, the plates (302 to 306) of the switching assembly 204 may be mounted on the rails (e.g., the first rail 116 and the second rail 118) of the first rail assembly 112.

[0052] According to various exemplary embodiments described herein, switching plate 302 may include a switching member (not shown), bridging plate 304 may include a bridging member (not shown), and steering plate 306 may include a steering member (not shown). In this respect, the switching member, bridging member, and steering member may respectively define a switching guide path, a bridging guide path, and a steering guide path for the pusher to move within these paths and further to the steering track path defined by steering guide 206. For this purpose, in Figure 4 The path defined by the corresponding plate of the switching assembly 204 is shown. Additionally, according to some exemplary embodiments described herein, the switching plate 302 may include a switching device (not shown) actuated by an actuator unit and movable between two positions (a first position or a second position) to selectively steer the pusher from its original path X to the steering guide path Y of the steering unit 202, further details of which will be referred to... Figure 4 The following description is provided. As shown in the figure, the switching plate 302 can be mounted on the rails 116 and 118 of the first rail assembly 112 and located between two adjacent cross braces (110-1 and 110-2). Additionally, the steering plate 306 can be mounted on the rails 116 and 118 and located between two adjacent cross braces (110-2 and 110-3). Furthermore, in some exemplary embodiments, a bridging plate 304 can be mounted on the rails 116 and 118 and located above the cross brace 110-2 of the conveyor frame 104. Mounting the bridging plate 304 above the cross brace 110-2 prevents the cross brace 110-2 from interfering with one or more components of the switching plate 302.

[0053] According to the various exemplary embodiments described herein, guide rail assemblies (112 and 114) may support the mounting of one or more components of the steering unit 202 (e.g., but not limited to, switching assembly 204, steering rail 206, and end plate 208) onto the conveyor 102. For example, in some exemplary embodiments, the switching plate 302, bridging plate 304, and steering plate 306 of the switching assembly 204 may be mounted on guide rails 116 and 118 of the first guide rail assembly 112. For this purpose, these components may be mounted on the guide rails based on an engagement mechanism. That is, in some exemplary embodiments, the first guide rail assembly 112 may support the mounting of the switching assembly 204 based on an engagement mechanism including alignment keys and fastening mechanisms (e.g., bolts and nuts). In this regard, in some examples, mounting one or more plates of the switching assembly 204 may include aligning the plates with each other using alignment keys and / or aligning them on guide rails 116 and 118, further details of which will be provided later. Figures 4 to 8 The description is in the middle.

[0054] Additionally, according to some exemplary embodiments described herein, the plate of the switching assembly 204 may include a plurality of keyways (not shown) adapted to receive corresponding alignment keys. For example, as shown, the switching plate 302 of the switching assembly 204 may include a keyway that allows the alignment key 308 to pass through the keyway and further into a recess defined by the first guide rail 116 of the first guide rail assembly 112. Inserting the alignment key into the corresponding keyway of the plate of the switching assembly 204 aligns the plate and / or the switching assembly 204 on the first guide rail assembly 112. Thus, for some exemplary embodiments, each of the switching plate 302, the bridging plate 304, and the steering plate 306 may define a corresponding keyway configured to receive a corresponding alignment key for aligning the plates (302 to 306) on the first guide rail assembly 112. Additionally, refer to... Figures 4 to 8 The details of the alignment key and its engagement with the keyway of the plate of the switching assembly 204 are described.

[0055] Figure 4 A perspective view 400 shows a switching assembly 204 mounted on a first guide rail assembly 112 using multiple alignment keys (402 to 412) according to some exemplary embodiments described herein. Figure 7The structural details of the alignment keys (402 to 412) are described herein. Illustratively, the switching assembly 204 includes a plurality of plates (e.g., switching plate 302, bridging plate 304, and steering plate 306) positioned adjacent to each other. In this regard, in some examples, each plate (302 to 306) of the switching assembly 204 may be mounted on the first guide rail assembly 112 using an engagement mechanism (e.g., a pair of engagement mechanisms including alignment keys and nut and bolt assemblies). For this purpose, according to various exemplary embodiments described herein, the switching plate 302 may include a first keyway (not shown) adapted to allow a first alignment key 402 to pass through the first keyway and enter a recess (not shown) in the first guide rail, thereby aligning the switching plate 302 on the first guide rail 116. Additionally, in some exemplary embodiments, the switching plate 302 may include another keyway adapted to allow another alignment key 404 to pass through the other keyway and enter a recess. Additionally, the steering plate 306 may include a second keyway (not shown) adapted to allow a second alignment key 408 to pass through the second keyway and enter a recess in the first guide rail 116, thereby aligning the steering plate 306 on the first guide rail assembly 112. Furthermore, the bridging plate 304 of the switching assembly 204, positioned between the switching plate 302 and the steering plate 306, may include a third keyway. In this respect, the third keyway may be adapted to allow a third alignment key 406 to pass through the third keyway and enter a recess in the first guide rail 116, thereby aligning the bridging plate on the first guide rail assembly 112. The insertion of alignment keys 402 to 408 also allows plates 302 to 306 to be aligned with each other on the first guide rail assembly 112. According to various exemplary embodiments described herein, alignment keys 402 to 408 may pass through corresponding keyways on plates 302 to 306 from either end (i.e., from the top surface side or the bottom surface side of plates 302 to 306). In other words, alignment keys 402 to 408 can be inserted from either side of the steering component plate and function correctly for alignment.

[0056] As shown, the switching assembly 204 can be mounted on rails 116 and 118 of the first guide rail assembly 112 of the conveyor. In this respect, a first side 414 (e.g., the left edge) of the switching assembly 204 can be positioned above the first guide rail 116, and a second side 416 (e.g., the right edge) of the switching assembly 204 can be received within a groove longitudinally defined by the second guide rail 118. (See reference...) Figures 5 to 8 Further details are described in relation to engaging the alignment keys (402 to 412) in the grooves defined by the rails 116 and 118 of the first rail assembly 112.

[0057] According to some exemplary embodiments described herein, the conveyor 102 described herein may correspond to a slat slider sorting conveyor comprising a plurality of slats (e.g., having slats 401) mounted between two side frames of the conveyor 102 (e.g., a first side frame 106 and a second side frame 108). In this regard, according to some exemplary embodiments, the plurality of slats (or transverse slats) of the sorting conveyor 102 may generally be arranged parallel to each other and perpendicular to the direction of travel of the articles on the conveyor 102. In some examples, these transverse slats are typically carried at each end by a moving element, such as an annular chain track, which may include alternately arranged extension pins that directly or indirectly engage the slats to carry them. In other words, according to some exemplary embodiments, a plurality of pushers of the sorting conveyor 102 may travel transversely about the slats (relative to the direction of travel of the sorting conveyor) to deflect articles carried by the upper surface of the sorting conveyor 102 to a deflection channel. Therefore, the sorting conveyor 102 having the plurality of slats may correspond to a sorting conveyor that can be operated according to some of the techniques described in the following U.S. patent application: U.S. patent application US10 / 409,749, filed April 8, 2003, entitled “Sortation system, components and methods,” details of which are incorporated herein by reference.

[0058] See again Figure 4 Perspective 400 also shows the movement of the pusher along the path defined by the switching assembly 204. It should be understood that the pusher mentioned herein can correspond to an element that moves laterally along the length of the slat, i.e., an element that moves based on the pusher within the path defined by the switching assembly 204 and further by the steering guide 206. Therefore, for the sake of brevity, the pusher can be interchangeably referred to as a steering mechanism, steering element, pusher, and pusher element.

[0059] Examplely, the plates (302 to 306) of the switching assembly 204 may define multiple paths for the movement of pushers on one or more pushers of the conveyor 102. For example, the switching assembly 204 may define a first path 420 for the movement of pushers 422 on pushers 424. In this respect, movement of pushers 422 along the first path 420 may cause one or more articles on the conveyor 102 to turn to a turning position (e.g., connected to a turning channel of the sorting conveyor 102). In addition, the switching assembly 204 also defines a second path 426 for the movement of pushers 422 when the article turning is not desired.

[0060] According to the exemplary embodiments described herein, the first path 420 and the second path 426 can be defined based on the connection of various sub-paths defined by the components of the respective plates 302 to 306. In other words, the sub-paths mentioned herein can be defined by a plurality of components defined on the respective plates 302 to 306. In this regard, according to some exemplary embodiments described herein, the switching plate 302 may include a switching member, the bridging plate 304 may include a bridging member, and the steering plate may include a steering member that defines a respective sub-path for movement of the pusher 422 of the pusher block 424. The switching member, bridging member, and steering member mentioned herein may correspond to a structure defined by a metal casting mold or molding element that protrudes outward from the top surface of the respective plates (302 to 306). When the switching plate 302, the bridging plate 304, and the steering plate 306 are positioned abutting each other, the steering guide path defined by the steering plate 306 of the switching assembly 204 can be connected to a steering guide rail 206 located downstream of the switching assembly 204 of the steering unit 202.

[0061] According to some exemplary embodiments, the switching plate 302 may further include a switching device 428 configured to be rotatably moved to a first or second position on the switching member of the switching plate 302. In this regard, in some examples, in response to actuation, the switching device 224 may be rotated to move to the first position to allow movement of the pusher 422 along a first path 420. Alternatively, in some examples, the switching device 428 may be rotated to move to a second position to allow movement of the pusher 422 into a second path 426. For this purpose, in some exemplary embodiments, the pusher 422 of the pusher 424 is initially (i.e., prior to actuation) accommodated in its original position on the switching plate 302. However, in response to actuation, the pusher 422 may be moved onto the one or more paths defined by the switching assembly 204 to redirect the article from the sorting conveyor 102.

[0062] Figure 5 A perspective view 500 is shown of a switching plate 302 of a switching assembly 204 mounted between a first guide rail 116 and a second guide rail 118 of a first guide rail assembly 112, according to some exemplary embodiments described herein. According to some exemplary embodiments described herein, the guide rails (116 to 122) of the guide rail assemblies 112 and 114 may correspond to extrusions defined by materials such as aluminum. In other embodiments, other materials, metals, or composites may be used.

[0063] According to some exemplary embodiments, as shown, a first guide rail 116 may define a groove 502 along the length L of the first guide rail assembly 112. Additionally, a second guide rail 118 positioned parallel to the first guide rail 116 may include a top portion 504 and a bottom portion 506. In this regard, the top portion 504 may define a rail groove 508 adapted to receive a chain track (not shown) of the conveyor 102. Furthermore, the bottom portion 506 of the second guide rail 118 may define a longitudinal groove 510 along the length L of the first guide rail assembly 112.

[0064] Examplely, the switching plate 302 includes two sides, namely a first side 414 and a second side 416. In this regard, a longitudinal groove 510 defined on the second guide rail 118 is adapted to receive the second side 416 of the switching plate 302 of the switching assembly 204. That is, the switching plate 302 can be positioned on the first guide rail assembly 112 such that the first side 414 of the switching plate 302 is positioned above the first guide rail 116, and the second side 416 of the switching plate 302 is received within the longitudinal groove 510 of the second guide rail 116. Additionally, an alignment key 402 can pass through a keyway on the switching plate 302 into the groove 502, thereby aligning the switching plate 302 on the first guide rail assembly 112. Therefore, the switching assembly 204 can be installed on the first guide rail assembly 112 based on the second side 416 of the switching plate 302 to be positioned in the longitudinal groove 510 of the second guide rail 118 and the alignment key 402 to pass through the keyway on the first side 414 of the first guide rail 116 into the groove 502 of the first guide rail 116.

[0065] According to some exemplary embodiments, the rails (116 and 118) of the first rail assembly 112 support the slidable movement of the switching assembly 204. In this regard, the switching plate 302 is slidably movable along the length of the first rail assembly 112 when the alignment key 402 is inserted into the recess 502. For this purpose, the slidable movement of the switching plate 302 on the rails 116 and 118 of the first rail assembly 112 is based on the movement of the second side 416 of the switching plate 302 within the longitudinal recess 510 of the second rail 118 and the movement of the first side 414 of the switching plate 302 above the groove defined at the top surface of the first rail 116. Additionally, the switching plate 302 can be fixedly mounted on the rails 116 and 118 of the first rail assembly 112 by fastening the bolt and nut assembly 512 through the switching plate 302 into the recess 502.

[0066] Figure 6A cross-sectional view 600 is shown of a switching assembly 204 mounted on rails 116 and 118 of a first rail assembly 112 using a plurality of alignment keys (402 to 412) according to some exemplary embodiments described herein. Inventively, alignment keys 402 and 412 are inserted through corresponding keyways on a switching plate 302 of the switching assembly 204 into recesses 502 and 510 defined respectively by rails 116 and 118.

[0067] Figure 7 A perspective view 700 is shown of an alignment key 702 and a keyway 704 defined on a plate (e.g., switch plate 302) of a switching assembly 204 according to some exemplary embodiments described herein. Illustratively, the alignment key 702 may include a top portion 706, a bottom portion 708 extending from the top portion 706, and a hook 710 defined between the top portion 706 and the bottom portion 708. As shown, the periphery of the hole in the keyway 704 on the plate defining the switching assembly 204 may be defined as a shape complementary to the shape defined by the bottom portion 708 of the alignment key 702, thereby allowing the bottom portion 708 to insert through the keyway 704.

[0068] Additionally, in some exemplary embodiments, the hook 710 may be adapted to engage with the surface 712 of the switching assembly 204 when the alignment key 702 is inserted into the keyway 704. In this regard, according to some exemplary embodiments, the hook 710 may include an end defining a cantilever portion adapted to snap into a recess through the keyway 704 on the switching assembly 204, thereby abutting the surface 712 of the plate of the switching assembly 204. In other words, the alignment key 702 holds the switching plate 302 on the first guide rail assembly 112 when inserted into the recess 502.

[0069] Figure 8A cross-sectional view 800 of a second guide rail 118 defining a longitudinal groove 510 according to some exemplary embodiments described herein is shown. As shown, the second guide rail 118 defines two portions, namely a top portion 504 and a bottom portion 506. In this respect, as previously described, the top portion 504 defines a rail groove 508 (i.e., at the top surface of the second guide rail 118), which is adapted to receive the positioning of a chain track (not shown) connecting the plurality of slats of the conveyor 102. Additionally, as shown, the bottom portion 506 of the second guide rail 118 may define a longitudinal groove 510 for receiving a switching plate 302 of the switching assembly 204. According to the various exemplary embodiments described herein, the guide rails of the first guide rail assembly 112 of the conveyor 102 are designed such that one side of the plates (302 to 306) can slide into the groove 510 of the second guide rail 118, and then the other side of the plates (302 to 306) can be secured to the first guide rail 116 using the plurality of alignment keys (402 to 408) and fasteners. In this respect, the design interference between the top of the plates (302 to 306) and the top of the guide rails 116 and 118 securely holds the plates (302 to 306) in place. In other words, the design of rails 116 and 118 and alignment keys (402 to 412) achieves an interference fit (also known as a pressure fit or friction fit) of the components. That is, it achieves engagement of the components by friction after the components are pushed together (i.e., the alignment keys (402 to 412) engage within the grooves (502, 510) defined on rails 116 and 118), instead of using multiple fasteners and nuts to hold the plates (302 to 306) on the conveyor 102, thereby reducing hardware and installation costs.

[0070] It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural indicators, unless otherwise expressly stated.

[0071] References to “one embodiment,” “implementation,” “multiple embodiments,” or “one or more embodiments” in this specification are intended to indicate that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of this disclosure. The appearance of such phrases in various places in the specification does not necessarily refer to the same embodiment, nor is it a single or alternative embodiment mutually exclusive with other embodiments. Furthermore, various features that may be presented by some embodiments but not by others are described.

[0072] It should be noted that, when used in this disclosure, the terms “comprising,” “including,” and other derivatives of the root term “comprising” are intended to be open-ended terms that specify the presence of any of the said features, elements, integers, steps, or components, and are not intended to exclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

[0073] This document discloses detailed implementation schemes; however, it should be understood that the disclosed implementation schemes are merely exemplary and can be embodied in various forms. Therefore, the specific structural and functional details disclosed herein should not be construed as restrictive, but merely form the basis of the claims.

[0074] While it will be apparent that the exemplary embodiments described herein achieve the aforementioned objectives, it should be understood that many modifications and other embodiments can be devised by those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and embodiments that fall within the substance and scope of this disclosure.

Claims

1. A conveyor, the conveyor comprising: a first rail assembly extending along a length of the conveyor, the first rail assembly comprising a first rail defining a groove; and a turn unit comprising a switching assembly defining a key slot adapted to enable an alignment key to pass through the key slot and into the groove of the first rail, thereby aligning the switching assembly on the first rail, wherein the first rail assembly further comprises a second rail positioned parallel to the first rail, the second rail comprising: a top portion defining a rail slot adapted to receive a track of a chain of the conveyor; and a bottom portion defining a longitudinal groove adapted to receive a second side of the switching assembly.

2. The conveyor of claim 1, wherein, the key slot is adapted to receive an alignment key having: a top portion; a bottom portion extending from the top portion; and a hook defined between the top portion and the bottom portion, wherein the hook is adapted to engage a surface of the switching assembly when the alignment key is inserted into the key slot. the hook comprises a cantilevered portion adapted to snap fit into the groove through the key slot on the switching assembly, thereby abutting the surface of the switching assembly.

3. The conveyor of claim 2, wherein, the turn unit further comprises:

4. The conveyor of claim 1, wherein, a turn rail positioned downstream of the switching assembly; and an end plate positioned downstream of the turn rail.

5. The conveyor of claim 4, further comprising a conveyor frame and a second rail assembly, the first rail assembly configured to be positioned on a first portion of the conveyor frame, the second rail assembly configured to be positioned on a second portion of the conveyor frame along a direction of conveyance of the conveyor, the second rail assembly comprising: a third rail; and a fourth rail positioned parallel to the third rail, wherein the end plate of the turn unit is configured to be mounted on the third rail and the fourth rail of the second rail assembly. the switching assembly comprises at least one of a switching plate, a bridging plate, and a turn plate, each of the switching plate, the bridging plate, and the turn plate comprising a respective key slot adapted to receive a respective alignment key passing through one of a top surface or a bottom surface of the respective plate. the switching assembly comprises a first plate and a second plate mounted on the first rail assembly, and wherein the second plate is aligned with the first plate based on a first alignment key and a second alignment key respectively engaging into the groove passing through key slots defined on the first plate and the second plate.

6. The conveyor of claim 1, wherein, the switching assembly is bolt mounted on the first rail assembly, the bolt passing through a hole defined on the switching assembly into the groove, and wherein a nut is fastened over the bolt.

7. The conveyor of claim 1, wherein, the switching assembly comprises:

8. The conveyor of claim 1, wherein, a switching plate comprising:

9. The conveyor of claim 1, wherein, a top portion; ​ a first key slot adapted to enable a first alignment key to pass through the first key slot and into the groove of the first rail, thereby aligning the switch plate on the first rail; a divert plate comprising: a second key slot adapted to enable a second alignment key to pass through the second key slot and into the groove of the first rail, thereby aligning the divert plate on the first rail; and a bridge plate positioned between the switch plate and the divert plate, the bridge plate comprising: a third key slot adapted to enable a third alignment key to pass through the third key slot and into the groove of the first rail, thereby aligning the bridge plate on the first rail.

10. The conveyor of claim 1, wherein, the switch assembly is configured to be mounted on the first rail assembly based on a second side of the switch assembly to be positioned within a longitudinal groove of the second rail and an alignment key to be passed through a key slot on a first side of the first rail and into the groove.

11. The conveyor of claim 1, wherein, the switch assembly is configured to be slidably moved within the longitudinal groove and along a length of the first rail assembly.

12. The conveyor of claim 5, wherein, the divert unit is slidably movable along a length of the conveyor on the first rail assembly and the second rail assembly.

13. A divert unit for a conveyor, comprising: a first rail assembly extending along a length of the conveyor, the first rail assembly comprising a first rail defining a groove; and a switch assembly comprising a switch plate defining a key slot adapted to enable an alignment key to pass through the key slot and into the groove of the first rail, thereby aligning the switch assembly on the first rail, wherein the first rail assembly further comprises a second rail comprising: a top portion defining a track slot adapted to receive a chain track of the conveyor; and a bottom portion defining a longitudinal groove adapted to receive a second side of the switch assembly.

14. The steering unit of claim 13, wherein, the switch assembly is configured to be slidably moved within the longitudinal groove and along a length of the first rail assembly.

15. The steering unit of claim 13, wherein, the key slot is adapted to receive the alignment key, the alignment key comprising: a top portion; a bottom portion extending from the top portion; and a hook defined between the top portion and the bottom portion, wherein the hook comprises a cantilevered portion adapted to snap fit into the key slot and the groove defined by the first rail.

16. The divert unit of claim 13, further comprising: a divert track positioned downstream of the switch assembly; and an end plate positioned downstream of the divert track.

17. The divert unit of claim 16, further comprising: a second rail assembly configured to be positioned on a second portion of the conveyor frame in a direction of conveyance of the conveyor, the second rail assembly comprising: a third rail; and a fourth rail. a fourth rail positioned parallel to the third rail, wherein the end plate of the diverting unit is configured to be mounted on the third rail and the fourth rail of the second rail assembly.

18. A conveyor to divert articles to a diverted position, the conveyor comprising: a rail assembly extending along a length of the conveyor from one end of a conveyor frame to a second end of the conveyor frame, the rail assembly comprising: a first rail defining a groove along a length of the first rail assembly; and a second rail positioned parallel to the first rail; a switching assembly mounted between the first rail and the second rail when an alignment key is inserted into the groove of the first rail through a key slot defined on the switching assembly, wherein the second rail comprises: a top portion defining a rail slot adapted to receive a chain track of the conveyor; and a bottom portion defining a longitudinal groove adapted to receive a second side of the switching assembly.

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