Conveyor system for selectively diverting objects

Abstract

A conveyor system includes a conveyor belt having a plurality of article diverting conveyor belt rollers. An underlying drive roller assembly includes a plurality of pivotable roller carriages each having a freely rotatable drive roller that contacts a conveyor belt roller from below. An actuator engages an orientation device to pivot the carriage and change the orientation of the drive roller. The drive rollers can also move into and out of engagement with the conveyor belt rollers as their orientation is changed. The orientation device is clamped between three-dimensional support plates to adjust the orientation of the drive rollers relative to the belt rollers. A top support plate includes a corrugated vertical wall that forms a wear strip retainer. The orientation device can raise or lower the drive rollers during pivoting of the roller carriage. The drive roller assembly can be a modular assembly that can be customized for different sizes, shapes, and configurations.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 054,363, filed July 21, 2020, entitled “Conveyor System for Selectively Diverting Objects,” the contents of which are incorporated herein by reference.

[0003] background

[0004] The present invention generally relates to power-driven conveyors, and more particularly to conveyor systems having conveyor belts with object support rollers that rotate by contact with a drive mechanism having freely rotatable drive rollers whose orientation is changeable to cause the object support rollers to rotate in one direction or the other.

[0005] It is often necessary to redirect objects from a conveyor belt, for example, to another conveyor belt, in order to deliver or position these objects along a route to achieve one type of processing or another.

[0006] Matthew L. Fourney's U.S. Patent No. 7,506,751 (March 24, 2009) describes a conveyor system for turning an object carried on top of a conveyor belt with object support rollers. As the conveyor belt travels in the belt's direction of travel, the belt rollers rely on freely rotatable drive rollers that support the conveyor belt from below. The belt rollers are arranged in multiple lanes and rotate about an axis parallel to the belt's direction of travel. The drive rollers are mounted in pivotable cartridges. Actuators coupled to these cartridges pivot these cartridges and the drive rollers into position and contact the belt rollers. As the drive rollers pivot relative to the conveyor belt rollers at an angle, the belt rollers rotate to guide the conveyed object toward one side or the other of the conveyor belt, depending on the angle of the drive rollers relative to the belt's direction of travel.

[0007] Overview

[0008] One type of conveyor system embodying the features of the present invention includes: a conveyor belt having a plurality of conveyor belt rollers configured to deflect objects atop the rollers as the belt advances; and a drive roller assembly for selectively driving the conveyor belt rollers. The drive roller assembly includes a plurality of pivotable roller frames, each pivotable roller frame having an orientation element and a freely rotatable drive roller that contacts the conveyor belt rollers from below. An actuator engages the orientation element to pivot the frame and change the orientation of the drive rollers relative to the conveyor belt rollers. The drive rollers can also move to engage and disengage with the conveyor belt rollers as their orientation changes relative to the conveyor belt rollers. Abrasion strips can be inserted into recesses formed in the drive roller assembly to form a carryway across the width of the drive roller assembly. The drive roller assembly can be a modular assembly that can be customized for different sizes, shapes, and configurations.

[0009] According to one aspect, a drive roller assembly is provided for selectively actuating conveyor belt rollers in a conveyor belt, the conveyor belt rollers being configured to deflect an object on top of the conveyor belt rollers as the conveyor belt advances along a transport path. The drive roller assembly includes: a plurality of pivotable roller frames housing freely rotatable drive rollers that contact the conveyor belt rollers from below the conveyor belt; a three-dimensional top support plate; a translational orientation device for engaging the pivotable roller frames to change the orientation of the drive rollers relative to the conveyor belt rollers; and an actuator for selectively moving the translational orientation device to pivot the pivotable roller frames. The three-dimensional top support plate includes an array of openings arranged in a quincunx pattern. The roller frames extend through these openings. The three-dimensional top support plate includes at least one corrugated vertical wall extending longitudinally between a first and second row of openings on the top support plate, each corrugated vertical wall including a plurality of notches in its top edge for receiving abrasion strips. Each curve in the corrugated vertical wall partially surrounds an opening.

[0010] According to another aspect, a guide plate for driving a roller assembly includes: a planar substrate having a plurality of elongated openings; a cam mechanism including a frame opening for receiving a roller frame within the elongated openings; and a flexible blade connecting the cam mechanism to the planar substrate.

[0011] According to another aspect, an anti-abrasion strip retainer for driving a roller assembly includes: a longitudinally extending corrugated vertical wall; and a plurality of recesses in the upper edge of the wall for receiving the anti-abrasion strip.

[0012] According to another aspect, a method of assembling a drive roller assembly includes the steps of: inserting a plurality of fasteners into lateral top slots extending from the top wall of a support frame; and placing a plurality of bottom support plate modules on the support frame such that the plurality of fasteners are inserted through fastener openings in each bottom support plate module. Each bottom support plate module includes an array of bottom roller carrier openings. The method further includes the steps of: placing a translational orientation device on the plurality of bottom support plate modules, each translational orientation device including an array of elongated orientation openings, each elongated orientation opening including a linear array of teeth; and then placing a plurality of top support plate modules on the translational orientation device such that the plurality of fasteners are inserted through fastener openings in each top support plate module. Each top support plate module includes an array of top roller carrier openings. The method further includes the following steps: aligning and securing the edge top support plate module and the edge bottom support plate module to each other; aligning the remaining top support plate module and bottom support plate module relative to the edge top support plate module and the edge bottom support plate module using an alignment tool; securing the remaining top support plate module and bottom support plate module to each other; and aligning the translational orientation device relative to the top support plate module and bottom support plate module using an alignment tool, such that the bottom roller frame opening, the orientation opening, and the top roller frame opening are aligned to each other. The method then includes the following steps: attaching a movable actuator U-clamp to the translational orientation device; mounting the actuator and static actuator U-clamp within the support frame; and inserting the roller frame through the aligned top roller frame opening, orientation opening, and bottom roller frame opening. Attached Figure Description

[0013] The disclosed system and method can be understood with reference to the following figures. The components in the figures are not necessarily drawn to scale.

[0014] Figure 1 This is an isometric view of a portion of a conveyor system according to an embodiment, which can be adjusted to turn objects at various angles to either side of the system.

[0015] Figure 2 yes Figure 1 The front view of this part;

[0016] Figure 3 This is an isometric view of the drive roller assembly used for selective activation. Figure 1 Objects in a conveyor system are directed to the conveyor belt rollers;

[0017] Figure 4 yes Figure 3 A detailed close-up view of a portion of the drive roller assembly;

[0018] Figure 5 yes Figure 3Exploded view of the drive roller assembly;

[0019] Figure 6 It is used for Figure 3 End view of the support frame of the drive roller assembly;

[0020] Figure 7 This is an end view of another embodiment of the support frame for driving the roller assembly;

[0021] Figure 8 yes Figure 3 An isometric top view of the roller frame of the drive roller assembly;

[0022] Figure 9A yes Figure 3 Isometric view of the top support plate portion of the drive roller assembly;

[0023] Figure 9B yes Figure 9A Top view of the top support plate section;

[0024] Figure 9C yes Figure 9A A top view of the corrugated vertical wall of the top support plate section;

[0025] Figure 9D yes Figure 9C Another top view of the corrugated vertical wall;

[0026] Figure 10 It shows what is suitable for use Figure 3 Another embodiment of the roller carrier in the drive roller assembly;

[0027] Figure 11 yes Figure 3 A partially exploded view of a section of the drive roller assembly, showing the anti-wear strip and the anti-wear strip stop;

[0028] Figure 12 yes Figure 3 An isometric bottom view of the top support plate portion of the drive roller assembly, which has a set anti-wear strip and anti-wear strip stopper.

[0029] Figure 13 This is a cross-sectional view of the anti-wear strip, which is installed on... Figure 3 In the top edge of the top support plate of the drive roller assembly;

[0030] Figure 14 It is used for Figure 3 An isometric view of the anti-abrasion strip of the drive roller system, which has a notch to accommodate the anti-abrasion strip;

[0031] Figure 15 yes Figure 14 Side view of the anti-wear strip;

[0032] Figure 16 yes Figure 3 An isometric view of the sub-components of the drive roller component;

[0033] Figure 17 yes Figure 16 A breakdown diagram of the sub-components;

[0034] Figure 18 yes Figure 16 Detailed view of the bottom support plate of the sub-component;

[0035] Figure 19 yes Figure 16 An isometric top view of a portion of a child component;

[0036] Figure 20 yes Figure 16 Bottom view of the sub-component's translational orientation plate, U-clamp connector, and actuator;

[0037] Figure 21 yes Figure 16 Isometric side view of the translational orientation plate, U-clamp connector, and actuator of the sub-component;

[0038] Figure 22 This is a flowchart detailing the steps involved in assembling the drive roller assembly according to an embodiment of the present invention;

[0039] Figure 23 It is the drive roller assembly in Figure 22 A top view during the initial assembly step shown in the diagram;

[0040] Figure 24 yes Figure 23 A top view of the drive roller assembly after the translational directional plate has been placed on the bottom support plate module array;

[0041] Figure 25 yes Figure 24 Top view of the drive roller assembly after the top support plate module array is installed and during the alignment of the drive roller assembly components relative to each other;

[0042] Figure 26 It is in assembly Figure 25 An isometric view of the alignment tool used during the drive roller assembly;

[0043] Figure 27 yes Figure 25 Top view of the drive roller assembly during alignment of the secondary translational orientation plate;

[0044] Figure 28 yes Figure 27An isometric top view of the drive roller assembly during the attachment of the movable actuator U-clamp to the translational orientation plate;

[0045] Figure 29 yes Figure 28 Top view of the drive roller assembly during insertion of the drive roller module array;

[0046] Figure 30 This is an isometric top view of a portion of a drive subassembly according to another embodiment, the drive subassembly including a corrugated insert for modifying the drive assembly with anti-wear strips;

[0047] Figure 31 yes Figure 30 An isometric top view of the corrugated insert;

[0048] Figure 32 yes Figure 31 An isometric bottom view of the corrugated insert;

[0049] Figure 33 This is an isometric top view of a corrugated insert according to another embodiment;

[0050] Figure 34 yes Figure 33 An isometric bottom view of the corrugated insert;

[0051] Figure 35 yes Figure 33 Side view of the corrugated insert;

[0052] Figure 36 This is an isometric top view of a corrugated insert according to another embodiment;

[0053] Figure 37 yes Figure 36 A top view of the corrugated insert;

[0054] Figure 38 This is an exploded view of a sub-assembly including a compliance mechanism for directional drive rollers in the drive roller assembly for selective actuation. Figure 1 Object steering rollers in a conveyor system;

[0055] Figure 39 yes Figure 38 Assembly diagram of the sub-components;

[0056] Figure 40 yes Figure 38 and Figure 39 A top view of the panning directional panel in its default position;

[0057] Figure 41 yes Figure 40 Detailed top view of the cam mechanism of the translational directional plate;

[0058] Figure 42 yes Figure 41 A top view of the cam mechanism in its middle position;

[0059] Figure 43 yes Figure 41 A top view of the cam mechanism in a translational position. Detailed Implementation

[0060] As described above, while existing conveyor systems including conveyor belt rollers offer advantages over previous systems, they still have limitations.

[0061] Referring to the accompanying drawings, where similar numbers in several views indicate corresponding portions, Figure 1 and Figure 2 An embodiment of a portion of a conveyor system 100 is shown, which can be adjusted to turn objects at various angles to either side of the system. For example... Figure 1 and Figure 2 As indicated, the conveyor system 100 includes a region 104 comprising a roller conveyor belt 102 and an angle-adjustable "drive" roller module 106 located beneath the conveyor belt. Figure 1 and Figure 2 In one embodiment, the conveyor belt 102 includes a plurality of hingedly connected transverse modular conveyor belt modules 110. The belt is constructed from a series of rows of one or more belt modules connected laterally at hinge joints and end-to-end to form a loop that travels along a portion of the conveyor's transport path in the belt travel direction 114. The conveyor belt is reversible and can travel in a longitudinal direction opposite to direction 114.

[0062] One or more conveyor belt rollers 118 in conveyor belt module 110 include free-spinning conveyor belt rollers 118 for selectively turning objects carried by conveyor belt 102. Object support rollers 118 may be mounted on axles and extend longitudinally in the belt travel direction 114, such that the object support rollers 118 are capable of selectively turning objects to either side of the conveyor belt. For the purposes of this disclosure, the term "free-spinning" means that a roller is free to spin about its axis of rotation in either angular direction. Thus, roller 118 can be described as including "idler" rollers that will rotate freely in either angular direction when driven by an appropriate force. Figure 1 and Figure 2 In one embodiment, the roller 118 is positioned such that its axis of rotation is parallel to the belt travel direction 114. The roller 118 may alternatively be provided in another orientation.

[0063] The conveyor belt rollers 118 are made of metal and / or plastic or another suitable material and may be provided with a high-friction rubber or plastic outer layer or coating to prevent slippage when the rollers of the drive roller module 106 come into contact with the conveyor belt rollers. The rollers 118 are sized to extend beyond the upper and lower surfaces of the conveyor belt 102 (and the belt module body 112) so that they can both steer objects placed on the conveyor belt 102 and be selectively driven from below by the drive roller module 106, although the invention is not limited thereto.

[0064] refer to Figures 3 to 5 The region 104 comprised of angle-adjustable drive roller modules 106 includes one or more drive roller assemblies 200, each of which is individually controlled and actuated. The conveyor 100 may include a plurality of drive roller assemblies 200 arranged in various configurations to customize or otherwise change the number, arrangement, and / or size of the region 104 of drive roller modules 106. Each drive roller assembly 200 includes an array of drive roller modules 106 for selectively engaging conveyor belt rollers 118. Each drive roller module 106 includes a freely rotatable drive roller 218 housed in a roller carrier 220 to form an angle-adjustable roller module 106. Each roller carrier 220 is pivotable about a vertical axis to change the orientation of the drive roller 218. Rolling contact between the belt rollers 118 and the drive rollers 218 causes them to roll on each other and rotate as long as their axes are inclined relative to each other. In the illustrative array of drive rollers 218, each row of drive rollers is longitudinally offset from the adjacent row of drive rollers in a quincunx pattern (in the direction of travel 114) to increase the density of the array, though the invention is not so limited.

[0065] The roller carrier 220 is mounted via a shaped three-dimensional top support plate 320, which may include a plurality of modular plates extending laterally across the width of the assembly 200. The top support plate 320 includes a plurality of openings 316 arranged in longitudinal columns 318 and lateral rows 319. The columns of openings are laterally aligned with the lateral positions of the conveyor belt rollers 118, wherein adjacent columns are staggered relative to each other in a quincunx pattern to increase density, but the invention is not so limited. Each opening 316 rotatably receives the roller carrier 220 supporting a freely rotatable drive roller 218, which selectively engages the belt roller 118 in the corresponding column as the belt 102 advances in the belt travel direction 114. The openings 316 are shaped and three-dimensional, having vertical walls extending upward and external to a portion of each roller carrier, and forming abrasion strip receptacles and cam surfaces to selectively raise and lower the roller carrier 220, as described below.

[0066] A translational orientation device 420 engages orientation elements on a roller carrier 220 to selectively pivot the roller carrier 220 and its carried drive rollers 218 about their vertical axes. An actuator 460 selectively displaces the translational orientation device 420 laterally to pivot the roller carrier 220 about its vertical axes. In an illustrative embodiment, the translational orientation device 420 includes two spaced-apart translational orientation plates 420a, 420b connected together by a movable actuator U-clamp 432, such that the translational orientation plates 420a, 420b operate in unison. The translational orientation device 420 may include multiple modules arranged laterally across the width of the assembly 200, or may span the width of the assembly.

[0067] The bottom support plate 322 below the translational orientation device 420 may include a plurality of modular plates extending laterally across the width of the assembly 200. This bottom support plate is connected to the top support plate 320 and provides a lower support surface for the roller carrier 220. A frame opening 323 in the bottom support plate 322 receives the bottom portion of the roller carrier 220. The opening 323 in the bottom support plate 322 is vertically aligned with, but smaller than, the openings 316 in the upper support plate. In addition to restricting rotation of the roller carrier 220 about a fixed vertical axis, the openings 323 also help align the top and bottom support plates to facilitate assembly of the drive roller assembly. The bottom support plate 320 and the top support plate 322 are fixed relative to each other and are stationary, with the translational orientation device 420 slidably clamped between the support plates 320, 322. The illustrative top support plate 320 and the bottom support plate 322 may be formed of plastic or another suitable material. In one embodiment, the top support plate and / or the bottom support plate are formed by injection molding, 3D printing or another suitable process.

[0068] A support frame 400 beneath the bottom support plate 322 provides support for assembly 200. The illustrative support frame 400 comprises an extruded aluminum structural member with a channel shape. In another embodiment, the support frame 400 is formed from pultruded plastic, molded sheet metal, or any other suitable material and / or process. Attachment features (such as T-slots, clearance slots, and screw bosses) are formed in the support frame to attach other components of assembly 200 to the frame 400, as described below. Alignment tabs 410 on each side of the assembly engage with mating slots in the support frame 400 to precisely align the drive roller assembly 200 in the vertical direction.

[0069] A static actuator U-clamp 430 forms an attachment point to connect the fixed rod eye of the actuator 460 to the support frame 400. A movable actuator U-clamp 432 connects the dynamic rod eye of the actuator 460 to the translational guide plates 420a, 420b and connects the plates 420a, 420b to each other. The illustrative actuator 460 is a pneumatically actuated cylinder and piston that can selectively move the guide plate 420 to achieve rotation of the frame 220 and change the orientation of the drive roller 218; however, any suitable actuator can be used to selectively translate the guide device 420 to change the orientation of the drive roller 218.

[0070] Additionally, the drive roller assembly 200 includes abrasion strips 260 that form the transport path of the conveyor belt 102, thereby supporting the conveyor belt across its width. The illustrative abrasion strips extend in the belt travel direction 114 and across the length of the assembly 100, and are spaced apart between every other row 318 of the drive rollers. The illustrative abrasion strips are formed from UHMW-PE by extrusion, but the invention is not so limited. Recesses in the upper surface of the upper support plate 320 are designed to hold the abrasion strips 260 in selected positions relative to the drive rollers 218, as described below.

[0071] refer to Figure 6 The illustrative support frame 400 includes vertical sidewalls 420, 422, a vertical inner wall 421, and a horizontal top wall 430. A lateral top groove 402 extends from the horizontal top wall 430 to receive fasteners for connecting a top support plate 320 and a bottom support plate 322 to the support frame 400, and fasteners for connecting an alignment tab 410 to the support frame. The illustrative top groove 402 is formed by a vertical groove wall 403 and a horizontal upper wall 404 to form an inverted "T"-shaped groove. The support frame 400 includes internal grooves 461, 462 that extend laterally from the first vertical sidewall 421 and the vertical inner wall 421 and face inward for mounting an actuator 460. Lateral openings 471, 472, 473, 474 receive fasteners to secure the support frame 400 to the conveyor frame. Each lateral fastener opening 471, 472, 473, 474 is located below T-slots 402, 461, or 462, but the invention is not so limited.

[0072] The support frame 400 houses the actuator 460, as well as the static U-shaped clamp 430 and the movable U-shaped clamp 432. Lateral clearance grooves 405 in the top wall 430 (see...) Figure 5 The movable U-clamp 432 receives a boss. The movable U-clamp boss receives a fastener to secure the movable U-clamp 432 to the guide plate 420, thereby enabling translation of the connected guide plates 420a and 420b when the actuator 460 moves the movable U-clamp 432, as described below.

[0073] The illustrative support frame 400 extends approximately 6 inches in the longitudinal direction 114, which is the direction of travel of the conveyor belt.

[0074] For shorter support frames 490, such as Figure 7 As shown, the central support wall 421 can be omitted, and the lateral T-shaped top grooves 402' are closer together, depending on the desired configuration.

[0075] In the illustrative embodiment, rotation of the roller carrier 220 is used not only for orienting the associated drive roller 218, but also for raising the drive roller 218 to engage with the conveyor belt roller 118 and / or lowering the drive roller to disengage from the conveyor belt roller. In a non-steering orientation, the drive roller 218 is lowered to disengage from the conveyor belt, while in a steering orientation, the drive roller 218 is raised to engage with the conveyor belt. For example, refer to... Figure 8 , Figure 9A and Figure 9B In one embodiment, one, several or all of the roller carriers 220 may include a cam surface that causes the roller carriers 220 to automatically rise relative to the top support plate 320 when the actuator 460 orients the roller carriers 220 in a selected position.

[0076] The illustrative self-elevating roller carrier 220 includes a retainer ring 222 having a diameter-opposing hole 224 supporting the end of the axle 219 of the drive roller 218. A downward-facing cam surface 228 is formed on the bottom of the retainer ring 222. The downward-facing cam surface 228 is connected to the top support plate 320 (in... Figure 9A and Figure 9B The upward-facing cam surface 328 of the external opening 316 shown in the diagram works together to receive the roller carrier 220 in the opening, selectively raising and lowering the retainer ring 222 as the roller carrier pivots about its vertical axis. The illustrative cam surfaces 228, 328 are convex, having ramped sections to achieve vertical movement of the drive roller 218 during pivoting about the vertical axis, but the invention is not so limited.

[0077] refer to Figure 8The upper journal 229 extends downward from the retainer ring 222 and surrounds the bottom of the drive roller. The lower journal 232, located away from the retainer ring 222, has a smaller diameter than the upper journal 229. The periphery of the lower journal 232 is recessed inward from the periphery of the upper journal 229. In its upper portion, the lower journal 232 includes a sector of gear teeth 236 or another suitable directional element for engaging the translationally oriented device 420 to induce rotation of the roller carrier 220. Other suitable devices may be used to orient the roller carrier. In the illustrative embodiment, the tips of the gear teeth 236 do not extend beyond the periphery of the upper journal 229. The illustrative teeth 236 also do not extend around the entire periphery of the lower journal 232, thus leaving a toothless space in the upper portion of the lower journal 232. The distal end of the lower journal may include a locking tab 237 that engages with a slot formed in the bottom support plate 322, as described below, to prevent the roller carrier 220 from disengaging during operation.

[0078] exist Figure 10 In another embodiment shown, the roller carrier 520 includes a flat bottom 528 on the underside of a retainer ring 522 (which straddles the surface 328 of the top support plate) to produce rotationally oriented motion without vertical linear motion. In this embodiment, the drive roller 218 maintains constant contact with the belt roller 118. The roller carrier 520 is otherwise similar to the roller carrier 220, including teeth 536, a lower axle journal 532, and a locking tab 537.

[0079] refer to Figure 9A , Figure 9B , Figure 9C , Figure 9D , Figure 11 and Figure 12 The illustrative top support plate 320 is three-dimensional and modular, with each module including a planar base plate forming roller frame openings 316, these openings having shaped cam surfaces 328 forming the edges of the roller frame openings 316. The openings 316 are arranged in a quincunx pattern, wherein adjacent columns are longitudinally offset from each other such that the openings in one column are staggered and positioned in the middle between the openings of adjacent columns. The illustrative top support plate module 320 includes four staggered columns and six staggered rows, for a total of twelve openings, but the invention is not so limited, and the top support plate module may include any suitable number and arrangement of openings. Multiple top support plate modules 320 may be arranged laterally along the width of the drive roller assembly 200, depending on the width of the specific conveyor belt used with the drive roller assembly 200.

[0080] The vertical upper wall 360 extends upward from the planar base and terminates in the upper edge including the shaped recess 361, thereby forming a retainer for the anti-abrasion strip 260. For example... Figure 9A , Figure 9B , Figure 9C and Figure 9D As shown, in the illustrative embodiment, the vertical upper wall 360 includes alternating, substantially corrugated vertical walls extending longitudinally in the travel direction 114 between adjacent columns of the opening 316. Each corrugated upper wall 360 has a curve surrounding at least a portion of the opening 316 in each adjacent column. When the modular drive assembly 200 is assembled, the corrugated vertical walls also surround at least a portion of the roller carrier 220 inserted into the opening 316. The vertical upper walls 360 alternate between columns, thereby leaving space between every other column. In one column, the vertical wall 360 wraps around a first side of the opening 316, while for an adjacent column, the vertical wall 360 wraps around a second side of the opening 316 in the second column. The illustrative top support plate module 320 includes two corrugated vertical walls 360: a first corrugated vertical wall extending longitudinally between the first and second column openings 316, and a second corrugated vertical wall extending longitudinally between the third and fourth column openings 316, but the invention is not so limited.

[0081] The illustrative anti-wear strip recess 361 is formed at the inflection point of the corrugated vertical wall, but the invention is not so limited. The illustrative recess 361 is dovetail-shaped to compressively engage the spherical protrusions on the anti-wear strip 260, as described below. The recess 361 can provide an interference fit to secure the anti-wear strip 260, as described below.

[0082] In an illustrative embodiment, the face of the corrugated vertical wall 360 facing the opening 316 is bent to match the shape of the opening 316, while the opposite face 368 not facing the opening 316 may be flat, but the invention is not so limited. Additionally, the corrugated vertical wall 360 at selected or all of the apexes and grooves may include notches 365. The corrugated vertical wall 360 may further include buttressing extensions to provide additional support to the structure. In an illustrative embodiment, the buttressing extensions include curved gussets 367 having a top surface 369 angled downward toward the cam surface 328. The illustrative curved gussets 367 are formed next to each apex between the second and third rows of openings 316 and between the fourth and fifth rows of openings, wherein shorter gussets 363 extend from the corrugated wall opposite each curved gusset 367 of each notch 365. Each curved gusset 367 intersects the main portion of the corrugated wall and forms a shallow "S" shape with another curved gusset 367 extending along the opening 316 in the adjacent column. The gussets 363, 367, together with the flat wall 368, form a vertical groove that extends along and downward from each recess 365 for receiving... Figure 11 and Figure 12 The anti-wear strip stop 265 shown.

[0083] like Figure 9D As shown, the corrugations in the corrugated vertical wall 360 have a wavelength λ and a pattern that repeats more than 2.5 times along the longitudinal length of the top support plate module 320. At the first end, the corrugated vertical wall 360 begins at the first apex 370 and bends into the first groove 371. Shorter gussets 363 extend from the corrugated vertical wall 360 at the first inflection point 373. From the groove 371, the vertical wall bends toward the second apex 374, where bent gussets 367 extend from the corrugated vertical wall at the second inflection point 375. Abrasion-resistant grooves 361 are formed at the inflections 374 and 375 of the top edge. The pattern then repeats until the end of the top support plate module 320. Although the illustrative corrugated vertical wall 360 is continuous along the length of the top support plate 320, alternatively, the corrugated vertical wall 360 may be discontinuous.

[0084] The illustrative top support plate 320 further includes fastener openings 386, 387 (e.g.) Figure 9A (As shown in the illustration), these fastener openings are for receiving fasteners to secure the top support plate 320 to the bottom support plate 322 and the support frame 400, as described below. In an illustrative embodiment, the corner fastener opening 387 is larger than the other openings 386 to receive fasteners with bushings, as described below.

[0085] like Figure 11 and Figure 12 As shown, the anti-abrasion strip stop 265 can be engaged in the top support plate 320 at the downstream end of the drive roller assembly to prevent the anti-abrasion strip 260 from sliding downstream, wherein the support leg is received in one or more recesses 365. Each top support plate 320 or an optional top support plate (such as the most downstream top support plate module in the drive roller assembly 200) may include the stop 265.

[0086] The illustrative anti-wear strip stop 265 includes: an upper anti-wear strip portion 266; a pair of legs 267, 268 on a first side of the upper anti-wear strip portion 266; and an offset leg 269 at the longitudinal midpoint of the anti-wear strip stop 265, on a second side of the upper anti-wear strip portion. Each of the legs 267, 268, and 269 includes an upper connecting portion 271 configured to receive in a recess 365 in a corresponding corrugated vertical wall 360. Each of the legs 267, 268, and 269 is received in a vertical groove formed between the gusset plate 363, the flat wall 368, and the curved gusset plate 367 (the vertical groove extends along and downward from the recess 365) to lock the anti-wear strip stop 265 to the top support plate 320. The upper portion 266 of the anti-wear strip is configured to align with the anti-wear strip 260 inserted into the upstream portion of the top support plate 320. This upper portion includes a flange 272 received in a recess 361 to position the anti-wear strip stop 265 in place. The flange 272 may be shaped to provide clearance for the roller carrier 220. When inserted, as... Figure 12 The anti-abrasion strip stop 265 shown provides continuity to the anti-abrasion strip surface, while the longitudinal restraint provided by the legs 267, 268, 269 prevents the weight and movement of the conveyor belt from causing the anti-abrasion strip(s) 260 to slip out of place.

[0087] In one embodiment, the abrasion strip 260 includes spherical protrusions 262 on its bottom surface, which are received in recesses 361 via compression fitting. Figure 13 As shown in the illustration. The illustrative spherical protrusion 262 may include straight, diverging sides and a curved, convex bottom surface, but the invention is not so limited. The fit between the protrusion 262 and the recess 361 is designed to have space between the bottom of the protrusion 262 and the bottom of the recess 361, but the invention is not so limited.

[0088] The anti-abrasion strip 260 can be manufactured as a straight extrusion that can be slightly bent to fit into the recess 361. For example, the anti-abrasion strip receiving recesses 361 can be slightly offset from each other to create a serpentine path, and the anti-abrasion strip 260 can be bent during insertion to form a serpentine shape. The serpentine shape in the anti-abrasion strip 260 prevents or restricts the anti-abrasion strip 260 from slipping during operation.

[0089] exist Figure 14 and Figure 15 In another embodiment shown, the abrasion strip 1260 includes a notch 1263 between protrusions 1262 to provide geometric locking with the top support plate 320. Figure 14 and Figure 15 In one embodiment, the protrusion 1262 has a straight side, a side indentation, and a bottom spherical part with a curved side and a flat bottom, but the invention is not so limited.

[0090] refer to Figure 16 and Figure 17 The drive roller assembly 200 may include multiple top support plate modules and bottom support plate modules, which are connected to each other to form a sub-assembly 201 that receives the array of drive roller modules 106. Several modular sub-assemblies 201 may be attached to the support frame 400 as needed to create drive roller sections 104 with different widths suitable for configuring a particular conveyor belt. Furthermore, as described above, the length of the drive roller section 104 can be varied using several drive roller assemblies 200.

[0091] Each sub-assembly 201 may include a sub-array of drive roller modules 106, each drive roller module including a roller frame 220 that houses drive roller sub-218, as described above. Bracket bolts 202 or other fastening devices extending through aligned fastening openings clamp the top support plate module 320' and the bottom support plate module 322' together. Alignment and fastening devices 203 (which include bracket bolts 202 or other fasteners with metal bushings) are used at one corner of the sub-assembly to align and anchor the sub-assembly 201 to the support frame. Alignment and fastening devices 203 do not clamp the top and bottom support plates, but instead clamp the lower fasteners to the lower support frame 400. Alignment and fastening devices 203 create a robust metal-to-metal connection to align each sub-assembly 201 along the width of the area. Alignment slots 402 in the top of the support frame 400 receive the heads of bolts 202 and 203 to secure the sub-assembly 201 to the support frame and to hold the components together. The orientation device 420 is slidably received between the top support plate module 320 and the bottom support plate module 322'.

[0092] refer to Figure 18 The bottom support plate module 322' includes a planar substrate 327 having a frame opening 323 for receiving the lower shaft neck 232 of the roller frame 220. During assembly, these openings align with and are below the opening 316 in the top support plate 320. The opening 323 includes a vertical slot 324 for receiving a tab 237 on the bottom of the roller frame 220. The tab 237 passes through the slot 324 during assembly and then clears a lip 381 forming the edge of the opening 323. Below the lip 381, the opening 323 provides a nearly full circumference clearance to allow the roller frame 220 to rotate freely within the opening 323, wherein a stop protrusion 382 extends downward from the lip 381 diagonally opposite to the slot 324. The lip 381 prevents the roller frame 220 from popping out of the opening 323.

[0093] During operation, the movement of the sheet material of the translational orientation device 420 is limited by the stroke of the pneumatic actuator 460, preventing the tab 237 and the groove 324 from aligning and thus preventing the roller carrier 220 from leaving the opening 323. Only when the pneumatic actuator 460 is disconnected can the translational orientation device 420 move to the "maintenance position," where the roller carrier 220 can be removed by aligning the roller carrier tab 237 and the base plate groove 324 and pulling the roller carrier 220 vertically.

[0094] A vertical buttress 326 extends from the top of the planar substrate 327 and can be integrally formed therewith, and includes an opening for the fastener 202. The illustrative buttress 326 provides vertical support for the top support plate 320. The illustrative buttress 326 includes a flat, vertical end face 384 forming a wear surface that contacts and guides the translationally movable orienting device 420. During assembly, the buttress 326 extends between the two orienting plates 420a, 420b. The illustrative buttress 326 further resists, reduces, and / or prevents gear separation forces that may be present in the system. The illustrative buttress 326 includes recesses 385 for maintaining a substantially uniform wall thickness through the feature to facilitate moldability, but these recesses 385 or other features shown are not required by the present invention.

[0095] The bottom support plate 322 further includes: a vertical boss 342 having another fastener opening for the fastener 202; and an alignment boss 343 at the corner having a larger opening for aligning and fastening the device 203. The vertical boss 342 and the alignment boss 343 are formed along a laterally extending edge of the bottom support plate, which may be an upstream edge, but alternatively, a downstream edge of the module. The base plate module 322' further includes guide features 341, which may also be integrally formed with the planar substrate 327. The guide features 341 extend upward from one side of at least some of the openings 323 and constrain the movement of the translational orientation device 420.

[0096] Additionally, the illustrative bottom support plate 322 includes lateral guide rails 329 that provide additional vertical support for the translational orientation device 420. The illustrative guide rails 329 contact the translational orientation device 420 in a location free of gear teeth or other laser-cut features to prevent wear on the lateral guide rails. The space between the lateral guide rails 329 allows some debris to fall off without disrupting the movement of the translational orientation device 420.

[0097] refer to Figure 19The illustrative translational orientation device 420 includes a main plate 420a and a secondary plate 420b. The orientation plates 420a and 420b are slidably clamped between a fixed upper support plate 320 and a bottom support plate 322, both of which, as described above, can include multiple modules. Each orientation plate 420a and 420b is positioned to engage the teeth 236 of the roller frame 220 to form a rack and pinion system that causes the roller frame 220 to rotate uniformly when the orientation plates 420a and 420b are translated by the actuator 460. These orientation plates have directional openings 444 that extend in the lateral direction. The elongated directional openings 444 are defined on one side by a linear array of teeth 446 forming a rack. Each elongated directional opening 444 is positioned below one of the roller carrier openings 316 in the top support plate 320, so that each elongated opening 444 can receive the lower axle neck 232 of the roller carrier 220. When the roller carrier is inserted, the lower axle neck 232 extends through the elongated directional opening 444 in the directional plate and into the smaller frame opening 323 in the lower bottom support plate 322. The laterally extending edges of the directional plates 420a, 420b (shown as upstream edges) also include teeth and are positioned to receive and engage selected roller carriers 220 in the array.

[0098] like Figure 20 As shown, the main plate 420a and the secondary plate 420b are separated by a space 424 to accommodate a row of vertical buttresses 326 extending from the bottom support plate 322, wherein a row of roller frames is received and accommodated in the space 424, as... Figure 19 As shown in the diagram. The main plate 420a has an end edge that is recessed from the end edge of the bottom support plate 320 to receive bosses 342, 343, such that when assembled, as Figure 19 As shown, bosses 342 and 342 are adjacent to the laterally extending outer edge of the main plate 420a.

[0099] Additionally, illustrative guide features 341 on the bottom support plate 322 are configured to extend between the toothless side of the elongated directional opening 444 and the lower journal 232 of the roller carrier 220. The flat side of each guide feature 341 contacts the inner edge of the corresponding elongated directional opening 444. These surfaces provide wear surfaces and resist any gear separation forces in the system. The absence of teeth on this portion of the lower journal 232 allows for the inclusion of guide features 341.

[0100] like Figure 20As shown, guide plates 420a, 420b are translated by a linear actuator 460 (such as a cylinder). One end of the actuator 460 is attached to a static actuator U-clamp 430, which connects the retaining lug of the actuator 460 to the support frame 400. The illustrative static actuator U-clamp 430 includes four fasteners 431 that engage T-slots 461, 462 along the inside of the support frame 400. These fasteners can be tightened during assembly to connect the static actuator U-clamp 430 to the support frame 400. At the other end, a movable actuator U-clamp 432 connects the actuator 460 to the guide plates 420a, 420b. The movable actuator U-clamp 432 includes a plate 433 and a plurality of bosses 434 that receive fasteners 435 to connect to two directional plates 420a, 420b, thereby linking the directional plates together and allowing them to operate in a consistent manner.

[0101] Return to reference Figure 19 Fastener 435 extends through opening 455 in the guide plate to secure the two guide plates 420a, 420b to the movable actuator U-clamp 432 and to each other. (Return to Reference) Figure 18 The bottom support plate 322 includes a slot 331 configured to allow fasteners 435 to slide within it. As described above, the support frame 400 also includes a slot 405 for the fasteners 435 to allow the translational orientation device 420 to slide.

[0102] refer to Figure 21 In one embodiment, the movable actuator U-clamp 432 may include a sliding element 436 on its bottom surface. The illustrative sliding element 436 is formed of a UHMW or another low-friction material to prevent the actuator 460 from rotating and to reduce friction between the actuator 460 and the movable actuator U-clamp 432. In another embodiment, the outer surface 437 of the slots 461, 462 of the static actuator facing the support frame 400 may include cross-hatching, knurling, or have another feature to increase grip between the support frame 400 and the static actuator 430.

[0103] Figure 22 A method for assembling a drive roller assembly 200, which includes modular top and bottom support plates, is shown. First, in step 120, a fastener 202 is slid into a support frame groove 402, such that the groove 402 holds the fastener head and the fastener shank extends upwards, as... Figure 23 As shown in the diagram. The number of fasteners 202 depends on the number of top support plate modules and bottom support plate modules to be used, with four fasteners for each top and bottom support plate module. Then, in step 122, the first bottom support plate module 322a is installed on the first set of fasteners, as shown. Figure 23 As shown in the diagram. The continuous bottom support plate modules 322x are similarly mounted on a continuous array of fasteners in a similar manner until the desired width is achieved. In step 124, the translational orientation plates 420a, 420b are placed on the bottom support plate modules, as shown. Figure 24 As shown. Figure 24 As shown, translational orientation plates 420a, 420b are placed on a bottom support plate module array such that each elongated opening 444 is located on an opening 323, a boss 326 with fastener 202 extends between the main plate 420a and the secondary plate 420b, and bosses 342, 343 are adjacent to the upstream lateral edge of the main plate 420a.

[0104] Then, in step 126, the top support plate modules 320a to 320x are installed by inserting each set of fasteners 202 through openings 386 and 387, wherein opening 387 covers and aligns with opening 343 of the bottom support plate module 322 below.

[0105] In step 128, the edge bottom support plate module 322a is positioned precisely relative to the edge of the support frame 400. Positioning can be accomplished using tools, markers, or another method that engages the edges of the bottom support plate.

[0106] In step 130, the edge top support plate module 320a and the edge bottom support plate module 322a are fastened together and secured to the support frame by the following steps: tightening nuts around the three fasteners 202, inserting bushings into the corner fasteners to form an alignment device 203, and tightening the fasteners to achieve a higher torque than the individual fasteners 202.

[0107] In step 132, the remaining top support plate modules and bottom support plate modules are positioned relative to the edge top support plate modules and edge bottom support plate modules, as well as the main translational orienting plate 420a. In one embodiment, a plurality of alignment tools 600 are used to position the remaining top support plate modules and bottom support plate modules relative to the edge modules, such as... Figure 25 As shown in the diagram. The illustrative method employs four alignment tools: two inserted into the edge top support plate module 320a and the edge bottom support plate module 322a, as well as the intermediate main orientation plate 420a, and two inserted into each consecutive top and bottom support plate module to align with the edge modules and the intermediate main orientation plate 420a. After positioning and clamping each group of modules using nuts on fasteners 202, a second set of alignment tools is inserted into the consecutive group of modules until all modules 320, 322 are clamped together and held to the underlying support frame 400, and the main orientation plate 420a is in place relative to the top and bottom support plate modules.

[0108] Figure 26 This is an isometric view of an alignment tool 600 adapted for aligning components of a drive roller assembly relative to each other during assembly. The alignment tool 600 includes a handle 610 and a head 620 configured to receive in and precisely align openings 316, 444, and 323 in an opening 316 of a top support plate, an elongated opening 444 of a guide plate 420, and an opening 323 of a lower bottom support plate. The head 620 includes a top knob 621 that engages in the bottom opening 323. The top knob 621 is substantially cylindrical, having a circular peripheral wall 622 and a rectangular protrusion 624 extending from an angled, converging flat wall 625. The protrusion 624 is configured to receive in vertical slots 324 in the bottom support plate 322 that receive tabs 237 on the bottom of the roller carrier 220. The top knob 621 is connected to a head base 626 via a neck 627. The base 626 is configured to receive and engage with an elongated opening 444 in the orientation plate. The base 626 includes rounded sides, a flat front wall and end walls, and a tapered protrusion 628 configured to engage a central tooth 446 of the opening 444 to precisely position the orientation plate 420 relative to the bottom support plate. Upon insertion, the alignment tool 600 holds the component parts together until the fastener 202 can be tightened, thereby securing the top support module and the bottom support plate module to each other and to the underlying support frame 400.

[0109] Then, in step 134, the secondary orientation plate 420b is aligned with the other components. In this step, as... Figure 27 As shown, the two lower alignment tools 600c and 600d are moved to the opening 316 on the secondary alignment plate 420b, while the two alignment tools 600a and 600b remain engaged with the primary alignment plate 420a to align and position the secondary alignment plate 420b relative to other components. As shown, during this step, the alignment tools 600a-d are located near the edge of the component.

[0110] In step 136, the movable actuator U-shaped clamp 432 is installed and attached to the translational orientation plates 420a and 420b. For example... Figure 28 As shown, while the alignment tool 600 is still inserted, the movable actuator U-clamp 432 is slid into the channel of the support frame 400, such that the boss 434 is aligned with the gap slot 405 of the support frame, the gap slot 332 of the bottom support plate module, and the opening 455 of the orientation plates 420a, 420b. Fasteners 435 can then be inserted through the aligned slots and openings and tightened to secure the movable actuator U-clamp 432 to the orientation plates 420a, 420b and to fix the orientation plates 420a, 420b to each other.

[0111] Next, in step 138, actuator 460 and static actuator U-clamp 430 are inserted into the channel of the support frame and loosely installed using fasteners, without fully securing the components together. Actuator 460 can then be tested to see if it correctly steers the translational guide plate.

[0112] In the subsequent step (step 140), the roller carrier 220 is installed to the assembly. In this step, the static actuator, although loosely installed, is not connected to the actuator cylinder. The translational orientation sheets 420a, 420b are manually pushed to the leftmost or rightmost "service" position, thereby exposing the vertical slot 324 in the base plate 323. The roller carrier 220 with drive rollers 218 can then be inserted through openings 316, 444, and 323, as... Figure 29 As shown in the diagram. After inserting all roller frames 220 and drive rollers 218, the translational orientation sheets 420a, 420b are moved to the central position, and the static actuator U-clamp 432 is securely attached to the actuator 460 using bolts or other suitable fasteners. Abrasion strips 260 can be inserted into abrasion strip retainer formed by the corrugated vertical walls in the top support plate. Abrasion strips 260 can be inserted before or after the roller assembly 220. The drive roller assembly 200 is then ready to selectively move the drive rollers 218 between a steering position and a non-steering position to selectively deflect objects on the conveyor belt running on the drive roller assembly 200.

[0113] According to another embodiment, the corrugated vertical walls of the top support plate 320 can be separated from the main portion of the top support plate to allow for modification, replacement, and / or cleaning of the corrugated vertical walls or for another purpose. For example, as Figure 30 As shown, the drive roller assembly 2200 may include a bottom support plate 2322 and a top support plate 2320, the top support plate including an opening 2316 for the roller assembly (not shown, but similar or identical to roller assemblies 220 or 520 described above). A corrugated insert 2360 is inserted between two rows of openings 2316 at selected lateral intervals, and includes a shaped recess 2361 in the upper edge of the corrugated insert, the shaped recess being configured to retain the anti-abrasion strip 2260.

[0114] Figure 31 and Figure 32An embodiment of a corrugated insert 2300 is shown, which can be used with a drive roller assembly to allow the drive assembly to incorporate an anti-wear strip. The illustrative corrugated insert 2300 includes a base 2362, two rows of offset openings 2317 configured to overlap with an opening in an upper support plate 2320, and a corrugated vertical wall 2360 between these rows. The illustrative openings 2317 include cam surfaces 2328 for selectively raising and lowering the drive roller carrier received in the openings 2317 during pivoting of the drive roller carrier about a vertical axis. The corrugated vertical wall 2360 includes a top recess 2361 for receiving an anti-wear strip 2260. Other features of the corrugated vertical wall 2360 (such as gussets and grooves) may be similar to the corrugated vertical wall 360 described above. The corrugated insert 2300 may include a connector (shown as bottom protrusion 2368) for attaching the corrugated insert 2300 to the top support plate, thereby integrating the anti-abrasion strip into the drive assembly. Other suitable devices may be used to integrate the corrugated insert 2300.

[0115] Figures 33 to 35 Another embodiment of a corrugated insert 3300 for a drive assembly is shown, enabling the insertion of an anti-wear strip across the width of the drive assembly. The corrugated insert 3360 includes a base 3362 from which corrugated walls 3360 extend. The corrugated walls 3360 include an upper recess 3361 for receiving the anti-wear strip. The illustrative insert 3300 does not fully externally connect to the opening 2316 of the upper support plate 2320, but the invention is not so limited. The insert 3300 further includes insertion tabs 3368 extending from the bottom of the base 3362 for connecting the corrugated insert 3300 to the top support plate, thereby integrating the anti-wear strip into the drive system. As described above, gussets, slots, and other features may also be included.

[0116] Figure 36 and Figure 37Another embodiment of a corrugated insert 3400 suitable for use with a drive roller assembly 2200 is shown. The corrugated insert 3400 includes a corrugated vertical wall 3360 extending from a first end to a second end and having a curve that partially circumferentially borders an opening in an adjacent column of an upper support plate 2320 of the drive roller assembly 2200 below. The illustrative insert 3400 includes one or more rounded edges extending from the vertical wall 3360, defining an opening 3417 that overlaps with an opening 2316 of the upper support plate 2320. The opening 3417 may include a cam surface for selectively raising and lowering the drive roller, thereby replacing selected cam surfaces in the upper drive plate as described above. The corrugated vertical wall 3460 includes a top recess 3461 for receiving an anti-wear strip. A curved gusset plate 3467 extends tangentially to the corrugated wall 3460 to provide additional support and engages between features of the upper support plate of the drive roller assembly below, which employs the insert 3400. The corrugated insert 3400 may include a connector (shown as a bottom protrusion 3468) for attaching the corrugated insert 3400 to the top support plate, thereby integrating the anti-abrasion strip into the drive assembly. Other suitable devices may be used to integrate the corrugated insert 3400.

[0117] In another embodiment, the translational orientation device for driving the roller assembly may include a compliant mechanism for causing the drive roller carriers to pivot about their vertical axis. (See reference) Figure 38 and Figure 39 The drive mechanism 1100 includes an array of drive rollers for selectively engaging object-carrying rollers in a conveyor belt to selectively deflect objects on the conveyor belt. The drive mechanism includes a plurality of pivotable roller frames 1220 for receiving freely rotating drive rollers (not shown). A fixed top support sheet 1320 includes a frame receiving opening 1316 and a fastener opening 1318 for connecting the top support sheet 1320 to a fixed bottom support sheet 1322. A translational orientation device 1420 is movably clamped between the top support sheet 1320 and the bottom support sheet 1322. The translational orientation device can slide back and forth to selectively pivot the roller frames about a vertical axis.

[0118] The top support plate 1320 may include a planar substrate 1321 including vertical walls 1360 having a top edge 1361 extending upward from the planar substrate and surrounding at least a portion of the opening 1316. The opening 1316 narrows at the bottom to form a shelf 1317 and a smaller opening 1319 at the bottom of the top support plate 1320. The top support plate may be formed of injection-molded plastic or another suitable material.

[0119] The illustrative roller holder 1220 includes a retainer ring 1222 having a diameter-opposing hole 1224 supporting the axle end of the drive roller. The bottom edge 1228 of the retainer ring 1222 rests on and rotates about the top edge 1361 of the top support plate 1320. An upper axle neck 1229 extends downward from the retainer ring 1222 and is housed within and pivotable in an opening 1316. A downwardly extending rod 1232 extends through a smaller opening 1318 and is received in a corresponding opening 1448 in a translationally oriented device 1420. The illustrative rod 1232 has a square or otherwise polygonal cross-section, but the invention is not so limited.

[0120] In one embodiment, the bottom edge 1228 of the retainer ring 1220 may be shaped to have a ramp section, and the top edge 1361 of the top support plate may also be shaped to cause the roller carrier 1220 to selectively raise and lower the driven rollers it carries when the roller carrier 1220 pivots about its vertical axis, as described above.

[0121] The illustrative translational orientation device 1420 includes a planar base plate 1421 with elongated openings 1444. These openings include a cam mechanism 1445 connected to a flexible blade 1446, which is connected to a main portion of the planar base plate 1421. The openings 1448 in the cam mechanism are sized and shaped to receive corresponding rods 1232 of a roller carrier. These openings are sized and configured such that rotation of the cam 1445 pivots the received roller carrier 1220. Although the illustrative openings 1448 and associated rods 1232 are square, the invention is not so limited and can include any geometry that rotationally locks components together. A boss 1447 extends downward from the bottom of the cam and is sized and shaped to receive in an opening 1323 in a bottom support plate.

[0122] The translation device 1420 further includes a slot 1449 to accommodate fasteners connecting the top support plate 1320 and the bottom support plate 1322.

[0123] The bottom support sheet 1322 includes a planar substrate 1324, which includes an opening 1323 for receiving a cam boss 1447. The opening 1323 can be raised relative to the substrate 1324. When assembling the assembly, a boss 1348 for receiving fasteners to connect the top support plate and the bottom support plate also extends upward from the substrate 1324 and extends through a groove 1449 into a fastener opening 1318.

[0124] An actuator (such as actuator 460 described above or another suitable device) selectively moves the translational orienting device to orient the roller frame. This actuator can slide the translational orienting device back and forth in a linear direction 150°, as... Figures 40 to 43 As shown, this is to cause the roller carrier to pivot. The illustrative cam 1445 may be fan-shaped, including diverging straight side edges 1452, 1453, a protruding curved rear edge 1454, and a larger protruding curved front edge 1455, but the invention is not so limited.

[0125] In default orientation (such as, Figure 40 and Figure 41 In the illustrative first orientation, cam 1445 is disposed in a first section of elongation groove 1444, the first section having a first side edge adjacent to a side edge 1449 of elongation groove 1444 and an opening 1448 for holding roller carrier 1220 in the first orientation. In the illustrative first orientation, the corresponding drive roller will roll in direction 1501. When the translation device is in direction 1502 (in Figure 35 As the plate 1420 moves (as shown in the diagram), the blade 1446, which connects the cam 1445 to the plate 1445, pushes or pulls the mating cam 1445 around its circumference, causing the cam 1445 to rotate. This cam is laterally fixed by the bottom support plate 1322. During rotation, the blade 1446 surrounds the circumference or leading edge 1455 of the cam 1445. Figure 42 In the central orientation shown, the drive roller will roll in direction 1503. The actuator can continue to move the orientation device to a fully translated position in direction 1502. Figure 43 (As shown in the diagram). In the fully translated position, the second side edge 1453 of the cam 1445 abuts the second side edge 1454 of the elongation slot 1444, which places the roller carrier in a third orientation in which the drive roller rotates in direction 1504, which is approximately 90° to the left of the first direction 1501. The roller orientation can be an infinite gradient between the default orientation and the fully translated orientation. The gradient level depends only on the type of actuator used. For example, a three-position pneumatic actuator assembly may only achieve left, right, and center. But an electric stepper motor with a ball screw can achieve these three positions plus all positions in between.

[0126] Other suitable devices can be used to selectively pivot the roller frame.

[0127] Although specific embodiments have been disclosed in detail in the foregoing description and accompanying drawings for illustrative purposes, those skilled in the art will understand that variations and modifications may be made thereto without departing from the scope of this disclosure.

Claims

1. A drive roller assembly for selectively actuating conveyor belt rollers in a conveyor belt, the conveyor belt rollers being configured to deflect an object on top of the conveyor belt rollers as the conveyor belt advances along a transport path, the drive roller assembly comprising: Multiple pivotable roller frames, each pivotable roller frame housing a freely rotatable drive roller that contacts the conveyor belt roller from below; Abrasion-resistant strips are configured to support the conveyor belt across the width of the drive roller assembly; A three-dimensional top support plate includes an array of openings arranged in a quincunx pattern, wherein the pivotable roller frame extends through the openings, and the three-dimensional top support plate includes at least one corrugated vertical wall extending longitudinally between a first column of openings and a second column of openings on the three-dimensional top support plate, each corrugated vertical wall including a plurality of notches in its top edge for receiving the anti-abrasion strip, wherein each curve in the corrugated vertical wall partially surrounds an opening; A translational orientation device for engaging the pivotable roller frame to change the orientation of the drive rollers relative to the conveyor belt rollers; and An actuator for selectively moving the translational orientation device to pivot the pivotable roller frame.

2. The drive roller assembly according to claim 1, wherein, The opening in the three-dimensional top support plate includes a shaped, upward-facing cam surface for raising the pivotable roller frame when it pivots to a selected orientation.

3. The drive roller assembly according to claim 1, wherein, The abrasion-resistant strip has spherical protrusions that are received in the recess.

4. The drive roller assembly according to claim 3, wherein, The notch is formed at the inflection point of the corrugated vertical wall.

5. The drive roller assembly according to claim 3, further comprising an anti-wear strip stop downstream of the anti-wear strip.

6. The drive roller assembly according to claim 5, wherein, The anti-wear strip stop includes: The upper portion of the anti-wear strip is configured to be aligned with the upper surface of the anti-wear strip; A pair of support legs on the first side of the upper portion of the anti-wear strip; and Offset support leg on the second side of the upper portion of the anti-wear strip.

7. The drive roller assembly according to claim 6, wherein, The corrugated vertical wall includes a vertical groove for receiving the legs of the anti-wear strip stop.

8. The drive roller assembly of claim 1, further comprising a second corrugated vertical wall between the third and fourth column openings for receiving the anti-abrasion strip.

9. The drive roller assembly according to claim 1, wherein, The corrugated vertical wall is integrated with the three-dimensional top support plate.

10. The drive roller assembly according to claim 1, wherein, The corrugated vertical wall is connected to the three-dimensional top support plate using connectors.

11. The drive roller assembly according to claim 1, wherein, The corrugated vertical wall includes a curved gusset plate having a top surface angled downward toward the opening.

12. The drive roller assembly according to claim 11, wherein, The face of the corrugated vertical wall facing the opening is bent to match the shape of the opening, and the face of the corrugated vertical wall opposite the opening is flat.

13. The drive roller assembly according to claim 1, wherein, The translational orientation device includes a movable plate with multiple lateral elongated openings, each elongated opening including a flexible blade for connecting a cam to the movable plate, wherein each cam has an opening for receiving a pivotable roller frame and rotatably locking thereto.

14. The drive roller assembly of claim 1, further comprising a three-dimensional bottom support plate, the three-dimensional bottom support plate being fixed to the three-dimensional top support plate and the translational orientation device being clamped between the three-dimensional top support plate and the three-dimensional bottom support plate.

15. The drive roller assembly according to claim 14, wherein, The three-dimensional bottom support plate includes guide features that extend through the translational orientation device.

16. The drive roller assembly according to claim 14, wherein, The three-dimensional bottom support plate includes a plurality of openings for receiving rods of the pivotable roller frame, each opening including at least one vertical slot for receiving a tab on the associated pivotable roller frame.

17. The drive roller assembly of claim 14, further comprising a support frame below the three-dimensional bottom support plate, the support frame having a channel shape for receiving the actuator.

18. The drive roller assembly of claim 17, further comprising a static actuator U-clamp for connecting the fixed rod eye of the actuator to the support frame, and a movable actuator U-clamp for connecting the dynamic rod eye of the actuator to the translational orientation device.

19. The drive roller assembly according to claim 18, wherein, The translational orientation device comprises two spaced-apart sheets connected by the U-shaped clamp of the movable actuator.

20. The drive roller assembly according to claim 1, wherein, The three-dimensional top support plate includes multiple modular plates that extend laterally across the width of the drive roller assembly.

21. The drive roller assembly according to claim 1, wherein, Each pivotable roller frame includes a sector of gear teeth that do not extend around the entire periphery of the pivotable roller frame to engage teeth on the translational orientation device.

22. The drive roller assembly according to claim 3, wherein, The notch is dovetail-shaped to compressively engage the spherical protrusions on the abrasion strip.

23. The drive roller assembly of claim 1, further comprising a plurality of circular edges extending from the corrugated vertical wall, the plurality of circular edges defining an opening that overlaps with the opening of the three-dimensional top support plate.

Images