Multi-directional conveyor drum

Abstract

An externally driven, manually driven, gravity driven, or non-driven conveyor roller having secondary rolling elements mounted in the core of the conveyor roller to reduce friction in the movement of product across the effective face of the roller in a direction opposite to the conveyor flow. The secondary rolling elements are arranged to rotate about an axis that is inclined relative to the path of the conveyor roller. All of the rolling elements can be oriented at substantially the same angle. The secondary rolling elements can be incorporated into secondary rolling element assemblies that can be readily fitted into openings defined in the core of the conveyor roller. Each assembly can be configured to snap fit into the openings in the core. In one embodiment, a pair of secondary rolling element assemblies can be configured to snap fit into the core from opposite sides and to interlock and support one another.

Description

Background Technology

[0001] This invention relates to roller conveyors, which use power-driven rollers (sometimes also called rollers), manually driven rollers, or gravity-driven rollers to transport products forward or backward along the length of the conveyor. In many material handling applications, whether the conveyor system is in motion or stationary, there is a need to move products laterally or across the width of the conveyor in directions other than the main direction of conveyor flow. Sliding friction between the product and the effective surface of the roller must be overcome to move the product in any direction other than the main direction of travel. Manually handling products to overcome lateral friction can lead to worker injury. Excessive lateral forces on the rollers can damage the roller bearings and the conveyor side frame. Existing solutions rely on a combination of multiple short conveyor rollers and multi-directional wheels mounted to a common axle. The number of individual components involved makes this option expensive. The solution is also inefficient due to excessive axle deflection caused by multiple components being supported by a single axle. Therefore, the demand for conveyor rollers that facilitate the movement of products in directions other than the main direction of travel remains long-standing and unmet. Summary of the Invention

[0002] The present invention overcomes the disadvantages of the prior art by providing a conveyor roller with a secondary rolling element mounted within the effective conveying surface and extending above the outer conveying surface of the roller, thereby reducing the force required to move products across the width of the conveyor when the conveyor system is in motion or stationary.

[0003] In one embodiment, the conveyor roller includes a shaft, a housing, and may also include one or more bearings that rotatably support the housing on the shaft. A plurality of secondary rolling elements are mounted within the housing and extend above the outer surface of the housing. These secondary rolling elements are oriented to rotate about an axis not parallel to the axis of the conveyor roller. In one embodiment, all of the secondary rolling elements rotate about complementary axes, which is significant in that they facilitate movement of the product in a common direction different from the primary direction of travel associated with the axis of rotation of the conveyor roller. For example, the secondary rolling elements may be arranged at substantially the same angle relative to the axis of rotation of the conveyor roller. The number and arrangement of the rolling elements may vary depending on the application.

[0004] In one embodiment, the invention includes a plurality of integral rolling element assemblies. Each rolling element assembly may include a housing, a shaft, and rolling elements. The shaft is rotatably mounted within the housing to provide a support structure for the rolling elements. Opposite ends of the shaft may be supported by bearings or bushings that facilitate rotation of the shaft, if desired. The rolling elements are mounted to the shaft and rotate with the shaft. In an alternative embodiment, the shaft may be fixed within the housing, and the rolling elements may be mounted to the shaft, possibly on bearings or bushings that facilitate rotation of the rolling elements about the shaft.

[0005] In one embodiment, each secondary rolling element assembly is mounted within the housing of the conveyor roller. The housing of each secondary rolling element assembly may be configured to fit snugly into an opening within the housing.

[0006] In one embodiment, the housing is configured to snap into a suitable position within a corresponding opening in the housing. In another embodiment, the housing includes a pair of protrusions configured to engage with and interlock with the housing. The housing and / or the protrusions may be made of a sufficiently flexible and resilient material to allow the protrusions to bend inward as they engage through the opening, but spring back outward to interlock.

[0007] In one embodiment, the secondary rolling elements are arranged around the conveyor drum in a pattern selected to maintain the structural integrity of the shell. For example, the secondary rolling elements may be arranged in rows extending circumferentially around the conveyor drum, and each row may be longitudinally offset from adjacent rows (or rows) such that the secondary rolling elements of one row do not overlap with the secondary rolling elements of adjacent rows (or rows) along the circumferential path.

[0008] This invention provides an efficient and durable conveyor roller assembly that facilitates the movement of products in directions other than those associated with the axis of rotation of the conveyor roller. The invention addresses both the cost and strength drawbacks of existing solutions by incorporating secondary rolling elements within the core of the roller. This reduces the overall cost of the assembly while improving strength by relying on a single rigid tube as the primary load-bearing element. The snap-in secondary rolling assembly facilitates assembly, repair, and replacement. It also allows for the interchangeable installation of different types of secondary rolling elements onto a given conveyor roller, for example, to accommodate different products or variations in the conveyor path.

[0009] These and other objects, advantages and features of the present invention will be more fully understood and appreciated by referring to the description and accompanying drawings of the present embodiments.

[0010] Before detailing the embodiments of the present invention, it should be understood that the present invention is not limited to the operational details or the details of the construction and arrangement of components set forth in the following description or shown in the accompanying drawings. The present invention may be practiced or implemented in various other embodiments and in alternative ways not explicitly disclosed herein. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be construed as limiting. The use of “comprising” and “including” and variations thereof means to cover items listed herein and their equivalents, as well as additional items and their equivalents. Additionally, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any particular order or number of components. The use of enumeration should also not be construed as excluding any additional steps or components that may be combined with or incorporated into the enumerated steps or components from the scope of the present invention. Attached Figure Description

[0011] Figure 1 This is a top view of a multi-directional roller according to an embodiment of the present invention.

[0012] Figure 2 This is a front view of the multi-directional roller.

[0013] Figure 3 This is a cross-sectional view of a multi-directional roller with a rolling element assembly according to the first embodiment.

[0014] Figure 4 This is a cross-sectional view of the rolling element assembly according to the first embodiment.

[0015] Figure 5 This is a cross-sectional view of an alternative multi-directional roller having a rolling element assembly according to the second embodiment.

[0016] Figure 6 This is a cross-sectional view of the alternative rolling element assembly according to the second embodiment.

[0017] Figure 7 This is a top view of another alternative multi-directional roller with a rolling element assembly according to the third embodiment.

[0018] Figure 8 It is with Figure 7 A top view of the conveyor rollers in the image shows its operation when configured as a steering mechanism. Detailed Implementation

[0019] Figure 1A first embodiment of the invention is shown, characterized by a conveyor roller 20 having a plurality of rolling elements 2 mounted in a roller core 1 in a pattern arranged around the effective width and length of a roller 4. The conveyor roller 20 is configured to rotate about a main axis 5 to allow supported products to move in a direction perpendicular to the main axis 5. In the illustrated embodiment, each rolling element 2 is oriented with its axis of rotation 6 perpendicular to the main axis (or the axis of rotation 5 of the conveyor roller core 1). Figure 2 As shown, the rolling elements 2 are positioned at or above the outer surface of the conveyor roller 20 such that they will engage with the product supported on the conveyor roller 20. The number, size, shape, and arrangement of the rolling elements may vary depending on the application.

[0020] This invention is described and illustrated in the context of a conventional conveyor roller 20, but it can be incorporated into a wide range of alternative conveyor rollers of different sizes, shapes, and constructions. For example, in some applications, the conveyor roller may be a dead-shaft roller with an integrated bearing that provides rotation of the housing relative to the internal shaft. In other applications, the conveyor roller may have a movable shaft, wherein the internal shaft and the housing are fixed together, and the conveyor roller rotates by using external bearing assemblies at opposite ends of the supporting shaft. Since such techniques are generally well known, other features and components of the conveyor roller 20 will not be described in detail.

[0021] In the illustrated embodiment, the conveyor roller 20 is a dead-axis roller, and the core 1 includes a shaft 22, a tubular housing 24, and a pair of bearing assemblies 26. The shaft 22 is configured to be fixedly (non-rotatably) mounted to the frame F supporting the roller conveyor assembly RCA (see, for example, see...). Figure 8 The housing 24 is concentrically disposed around the shaft 22 and rotatably coupled to the shaft 22 via a bearing assembly 26. In this embodiment, the bearing assembly 26 is conventionally operably fitted between the shaft 22 and the housing 24 at or near the opposite ends of the housing 24 to allow the housing 24 to rotate about the shaft 22. To accommodate the mounting of the rolling element assembly 28 (described in more detail below), the housing 24 defines a plurality of openings 40, each sized and shaped to tightly receive the rolling element assembly 28. More specifically, each opening 40 corresponds to the cross-sectional shape of the housing 3. In alternative applications, the construction of the conveyor roller 20 can be modified to accommodate different rolling elements and / or different rolling element assemblies.

[0022] In the illustrated embodiment, the rolling element 2 generally comprises a shaft 32 and a roller 34. The shaft 32 in the illustrated embodiment is a fixed shaft, meaning it is fixed and does not rotate with the roller 34. In an alternative embodiment, the shaft 32 may be a movable shaft configured to rotate with the roller 34. The shaft 32 and roller 34 may be manufactured separately from desired materials, and the two components may be assembled to form the rolling element 2. In this application, the shaft 32 may be metal, and the roller 34 may be injection molded from plastic. Highly lubricating plastics, such as PTFE or ultra-high molecular weight polyethylene (UHMW-PE), may be used to form the roller if desired, to facilitate rotation of the roller 34 about the shaft 32, although other plastics may be suitable depending on the application. In some embodiments, the shaft 32 and roller 34 may be a one-piece integral structure. For example, the shaft 32 and roller 34 may be simultaneously molded from a common material in a single injection molding step, or they may be molded from different materials in successive steps, such as by injection molding the shaft from a first material and subsequently injection molding the roller onto the shaft from a second material. As another example, the shaft can be prefabricated and the rollers can be injection molded into place around the shaft. These are merely examples, and the rolling element 2 can be manufactured using virtually any suitable manufacturing technology and equipment. In applications that include a moving shaft rolling element, the opposite ends of the shaft 32 can be supported by bearings, bushings, or other low-friction elements to facilitate the rotation of the shaft 32.

[0023] like Figure 2 As shown, the roller 34 is configured to partially project above the housing 24 and provide a contact surface that is generally parallel to the surrounding exposed surfaces of the housing 24. This is merely exemplary, and the size, shape, and configuration of the roller 34 may vary depending on the application. For example, the height of the roller 34 above the housing 24 and / or the length of the roller 34 may vary. As another example, the exposed surfaces of the roller 34 may have different shapes that are not parallel to the housing 34.

[0024] In the illustrated embodiment, each secondary rolling element 2 is integrated into an associated rolling element assembly 28, which in this embodiment is a self-contained unit (sometimes also called a stand-alone unit) mountable to the conveyor roller 20. In the illustrated embodiment, all of the rolling element assemblies 28 are substantially identical, and each rolling element assembly 28 mats with the conveyor roller 20 in substantially the same manner, meaning they can be interchangeably mounted at any location along the conveyor roller 20. In alternative applications, the rolling element assemblies 28 and mounting structures may vary depending on the location. In some applications, using a self-contained rolling element assembly may offer advantages, but alternative structures can be used to integrate the rolling elements 2 into the conveyor roller 20. For example, each rolling element 2 may be mounted directly to the conveyor roller 20 and is not integrated into the rolling element assembly 28.

[0025] In the illustrated embodiment, each rolling element assembly 28 includes a housing 3 and a rolling element 2 (wherein the illustrated rolling element 2 includes a shaft 32 and a roller 34). The illustrated housing 3 is generally rectangular and has a well of sufficient depth to receive most of the rolling element 2. The illustrated housing 3 also includes a tapered flange 7 surrounding the opening of the housing 3 and configured to sit flush with the surface of the housing 24 during installation. For example, the illustrated housing 3 includes a continuous flange 7 extending around the periphery of the housing 3 and, when installed in the conveyor roller 20, recessed into and flush with the exposed surface of the housing 24. The flange 7 is tapered to prevent it from pushing through the opening 40 into the interior of the housing 24. In the illustrated embodiment, the opening 40 is configured with a matching taper that allows the flange 7 to fit flush into the opening 40. The taper shown is merely exemplary, and the angle of the taper of the flange and the opening may vary depending on the application. It should also be understood that the flanges shown are merely exemplary, and the size, shape, and construction of the flanges may vary depending on the application. For example, the flanges may be discontinuous, or they may be larger or smaller. In alternative applications, the flange 7 may abut the housing 24 differently. For example, in some applications, the flange may completely or partially overlap the face of the housing 24. As another example, the periphery of each opening 40 in the housing 24 may be countersunk to receive all or part of the flange 7.

[0026] In the illustrated embodiment, each rolling element assembly 28 is configured to snap-fit ​​into a suitable position within the opening 40 in the conveyor roller 20; however, in alternative embodiments, the rolling element assemblies may be secured to the conveyor roller in other ways. To provide a snap-fit ​​configuration, the illustrated housing 3 includes a pair of outwardly extending locking protrusions 9 designed to abut against the housing 24 of the conveyor roller 20. For example… Figure 3 and Figure 4 As shown, the locking protrusion 9 extends outward from the housing 3. The locking protrusion 9 in the illustrated embodiment is shaped to facilitate insertion into the opening 40 while preventing removal. For example, the locking protrusion may have a somewhat pyramidal shape with a tapered surface, as shown. The degree of tapering can vary depending on the surface and application. For example, the inward-facing surface may be longer and have a more gradual taper (to facilitate insertion into the opening), and the outward-facing surface may have a steeper angle to help retain the rolling element assembly 28 within the housing 24. In the illustrated embodiment, the housing 3 is manufactured from a suitable plastic or polymeric material using generally conventional injection molding techniques and equipment. In alternative embodiments, the housing can be manufactured from virtually any alternative material suitable for the application, using corresponding manufacturing techniques and equipment.

[0027] In some applications, the rolling element assembly 28 can be sized to adjoin the shaft 22 extending through the center of the conveyor roller 20 or some other structure adjacent to the interior of the conveyor roller 20. This helps provide structural support to the rolling element assembly 28 by resisting inward movement of the assembly 28 relative to the housing 24. This option may be more practical in the context of moving-shaft conveyor rollers 20 and / or dead-shaft conveyor rollers in which the shaft has a circular cross-section.

[0028] exist Figure 3 In the illustrated embodiment, each rolling element assembly 28 is mounted in the housing 24 by pushing it into an opening 40 in the roller core 1 until it snaps into place. Features on the housing 3 (e.g., locking protrusions 9) are designed to flex inward to allow them to engage through the opening 40 in the roller core and return to their original position once in place within the roller core 1. These features prevent the assemblies from falling out of the roller as it rotates. A flange element 7 on the upper portion of the housing prevents the assemblies from falling further into the opening 40 and provides a means of supporting the product load. Figure 4 In the embodiment shown, each rolling element 2 rotates about a fixed axle 32 fitted into a housing 3. Each housing 3 contains a single rolling element 2, but this can vary in alternative applications. The rolling element assembly 28 shown is merely exemplary. The design and construction of the shown rolling elements 2 and rolling element assembly 28 can vary depending on the application (and potentially on their location on the same conveyor roller). Furthermore, the manner in which the rolling element assembly 28 is secured in the conveyor roller 20 can vary depending on the application. For example, the rolling element assembly 28 can be secured using alternative structures such as alternative snap-fit ​​components (e.g., one or more spring plungers), fasteners, chemical attachments, welding, and / or adhesives.

[0029] like Figure 5 and Figure 6As shown, a second embodiment of the invention features a rolling element assembly 28' with an additional extension 10' on the bottom of the housing 3', which allows two identical housings 30' to engage within the roller core 1'. In this embodiment, the two identical housings 30' engage into the housing 24' from opposite sides and around the shaft 22'. The housing extension 10' is characterized by tabs 11' or grooves 12' that mate with tabs 11' or grooves 12' of the identical housings 3' from opposite sides of the roller core. In some applications, tabs 11' and grooves 12' may be configured to interconnect to help maintain the connection between the two housing extensions 10' of adjacent rolling element assemblies 28'. For example, the tab 11' of one housing extension 10' may frictionally engage within the groove 12' of the other housing extension, or the tabs 11' and grooves 12' may include snap-fit ​​features (such as recesses and mating protrusions) that allow them to interlock with each other in a manner that prevents separation. This embodiment adds additional strength and is particularly useful when conveying heavy products and / or when impact loads may occur. When mated, the product load on one component 28' can be transferred to the second component 28', and the two components can share the load. The housing extensions 10' shown are merely exemplary and can vary depending on the application. For example, the size, shape, and construction of the extensions 10' can vary. In alternative applications, the connection mechanism can also vary. The number of interconnected rolling elements can vary depending on the application. For example, the housing extension can be configured to allow three or four rolling element assemblies arranged symmetrically around the conveyor roller 20' to interconnect.

[0030] The third embodiment of the present invention is in Figure 7 and 8 As shown, and characterized in that the rolling element 2” is oriented such that the axis of rotation 13” is at an angle to the axis of rotation 14” of the conveyor roller 20”. This embodiment is particularly useful in drive roller conveyors that employ methods to stop the forward movement of products, such as Figure 8As shown, although it may also be useful in other applications. When no other force acts on the conveyed product P1, it will travel along the conveyor in the flow direction D1, with the rolling element 2” moving very little. When product P2 is stopped from moving along the conveyor by the stop 23”, the support roller 24” below product P2 continues to rotate, which causes the rolling element 2” to rotate against the bottom surface of product P2. The tilting rotation angle of the rolling element 2” causes the first part of the rotation to counteract the rotation of the conveyor roller 20” and reduce the backline pressure on the product. The second rotating part applies a lateral force to product P2, causing it to move laterally along the face of stop 23” in the direction of arrow D2. The angle shown is merely exemplary, and the rolling element 2” can be oriented at substantially any angle relative to the axis of rotation of conveyor roller 24”. In some applications, the angle of the rolling element 2” may vary along the length of conveyor roller 24”. For example, the rolling element 2” on one opposite half of conveyor roller 24” may be oriented in different directions to move the product to the left or right depending on the product’s position on conveyor roller 24”.

[0031] The preferred embodiment is snap-fit, but other embodiments may be chemically bonded or otherwise fitted to the core. The preferred embodiment is made of injection-molded plastic, but other embodiments may utilize other materials or manufacturing methods depending on specific application requirements. The preferred embodiment has a one-piece rolling element made of a homogeneous material, but other embodiments may be made using a two-piece design, including a rigid inner portion that facilitates easy rotation, and an outer portion made of another material that provides application-specific benefits when in contact with the product. The preferred embodiment uses a separate metal shaft for the rolling element's axle, but other embodiments may have a plastic shaft incorporated into the housing design. The preferred embodiment is designed around an industry-standard 1.9” diameter conveyor roller, but can be easily extended to smaller or larger diameter roller applications. Figure 1 The preferred embodiment shown is characterized by a patterned arrangement of rolling elements to achieve a balance between tube strength and functionality. This pattern is designed to be modified to suit the needs of a specific application.

Claims

1. A conveyor roller, comprising: The roller core includes a conveying surface that is rotatable about a main axis. as well as Multiple rolling elements are installed within the roller core, each of which is capable of rotating about an axis different from the main axis of the core.

2. The conveyor roller according to claim 1, wherein, The rolling elements are arranged in a regular pattern around the circumference and length of the conveyor drum.

3. The conveyor roller according to claim 2, wherein, Each of the rolling elements extends above the conveying surface.

4. The conveyor roller according to claim 3, wherein, The rolling element is installed in a housing that matches the roller core.

5. The conveyor roller according to claim 4, wherein, Each of the rolling elements is capable of rotating about an axis perpendicular to the main axis.

6. The conveyor roller according to claim 4, wherein, Each of the rolling elements is capable of rotating about an axis inclined to the main axis.

7. The conveyor roller according to claim 2, wherein, The rolling elements are arranged around the circumference and length of the conveyor, wherein no more than two rolling elements are positioned along a single circumference.

8. The conveyor roller according to claim 2, wherein, The rolling elements are arranged in pairs around the circumference and length of the conveyor, wherein no more than one pair of rolling elements is positioned along a single circumference.

9. The conveyor roller according to claim 1, wherein, Each rolling element is rotatably mounted within the housing to define the rolling element assembly; Each housing includes at least one housing extension; and The rolling element assemblies are mounted in pairs, wherein the housing extension of one of the rolling element assemblies engages with the housing extension of the other of the rolling element assemblies.

10. A conveyor roller assembly, comprising: Multiple conveyor rollers positioned side by side; The first conveyor roller in the conveyor rollers includes: A first housing forming the first main rolling element, the first housing being rotatable about a first main axis; and A plurality of primary rolling elements are mounted within the first housing, each of which is rotatable about an axis different from the first main axis; and The second conveyor roller in the conveyor rollers includes: A second housing forming the second main rolling element, the second housing being rotatable about the second main axis; and A plurality of secondary rolling elements are mounted within the second housing, each of which is capable of rotating about an axis different from the second main axis; and The first conveyor roller in the conveyor rollers is arranged adjacent to the second conveyor roller in the conveyor rollers, whereby the first conveyor roller in the conveyor rollers and the second conveyor roller in the conveyor rollers cooperate to define the product conveying surface.

11. The conveyor roller assembly according to claim 10, wherein, The plurality of primary rolling elements are arranged in a regular pattern around the circumference and length of the first conveyor roller in the conveyor rollers; and The plurality of secondary rolling elements are arranged in a regular pattern around the circumference and length of the second conveyor roller in the conveyor roller.

12. The conveyor roller assembly according to claim 11, wherein, The plurality of primary rolling elements are arranged in pairs around the circumference and length of the first conveyor roller in the conveyor rollers; and The plurality of secondary rolling elements are arranged in pairs around the circumference and length of the second conveyor roller in the conveyor roller.

13. The conveyor roller assembly according to claim 10, wherein, Each of the plurality of primary rolling elements is rotatably disposed within the housing; and Each housing fits into a corresponding opening in the outer shell of the first conveyor roller.

14. The conveyor roller assembly according to claim 13, wherein, Each housing snaps into a corresponding opening in the outer shell of the first conveyor roller.

15. The conveyor roller assembly according to claim 14, wherein, Each housing includes a flange that operatively engages with the outer shell around an opening.

16. The conveyor roller assembly according to claim 15, wherein, Each of the plurality of first rolling elements includes an axle and a roller, the roller being arranged around the axle, the axle being snap-fitted into the housing.

17. The conveyor roller assembly according to claim 16, wherein, Each of the housings is identical and configured to sit in any one of the openings.

18. The conveyor roller assembly according to claim 17, wherein, Each of the housings includes at least one extension; and Each housing includes at least one housing extension; and The rolling element assemblies are mounted in pairs, wherein the housing extension of one of the rolling element assemblies engages with the housing extension of the other of the rolling element assemblies.

19. A conveyor roller, comprising: A shaft extending along the main axis; The housing is concentrically arranged relative to the axis, the housing has an outer circumferential surface to support the product carried by the conveyor roller and is rotatable about the main axis, the housing defining a plurality of openings; as well as A plurality of secondary rolling elements are installed within the housing, the plurality of secondary rolling elements being arranged in a regular pattern around the circumference and length of the housing, each of the secondary rolling elements including a shaft and a roller, the roller protruding above the outer circumferential surface of the housing and oriented to rotate about an axis different from the main axis.

20. The conveyor roller according to claim 19, wherein, Each of the plurality of secondary rolling elements is rotatably mounted in a housing, and each housing is fixed within a corresponding opening in the outer casing.

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