Method and apparatus for stabilizing carrier baskets moving on a conveyor system to maintain basket alignment at a loading / unloading station - Patents.com

Abstract

A carrier basket stabilization system and method for use with a conveyor system having a path over which vehicles are guided, at least some of the vehicles having carrier baskets pivotally mounted thereon. The conveyor system includes a curved portion of the path that may be immediately prior to at least one of a loading station or an unloading station. The system includes a support configured to be disposed adjacent a portion of the path, the deflectable element on the support extending generally parallel to the portion of the path, the deflectable element extending partially within a spatial envelope generated by the carrier basket as it moves through the portion of the path. The deflectable element includes bristles that resist outward rocking motion of the carrier basket.

Description

[Technical field]

[0001] The present invention relates to the field of conveyor systems used in moving goods, for example during order fulfillment in restaurant chains, bars, cafeterias, etc. More specifically, the present invention relates to a system for ensuring proper alignment of carriers moved by a conveyor as the carriers move into a loading and / or unloading station. [Background technology]

[0002] Applicant has developed and marketed an overhead conveyor system that is based on a continuous track configured in a closed loop with an end restraint made up of small wheeled vehicles connected together. The track is typically suspended from the ceiling or wall and can be configured to snake around the building from a loading point to an unloading point and back again. The food to be transported must be in packages or bags, which are placed in carrier baskets that are carried by some of the wheeled vehicles. Various means can be provided for unloading or releasing the packages or bags from the carrier basket and placing the food in the holding trays.

[0003] Another food transport system for vertical transport of packaged food products from one floor of a restaurant to another is described in U.S. Patent No. 7,708,135. The food transport system includes a conveyor that transports food support carriers along a closed loop path defined by a belt or chain to which the carriers are pivotally connected. Although convenient for transporting food products disposed on support carriers, belt or chain based conveyor systems offer little flexibility with respect to space utilization and tortuous transport paths.

[0004] The applicant's US2021 / 0094761 also focuses on a conveyor system for the transport of packaged food in restaurants and the like, the system allowing for flexible design of the layout. This can be realized as a truck-based conveyor system with a support carrier on which the food to be transported can be placed at a loading station. The food is then transported to a customer delivery point remote from the loading station. Here, the packaged food is loaded onto the carrier at the loading and unloading stations. In one preferred configuration, the carrier is defined by a basket having a series of support fingers, which are aligned with the spaces located between the support fingers or rollers of the loading / unloading stations. The entire contents of US2021 / 0094761 are incorporated herein by reference as if fully set forth. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] U.S. Patent No. 7,708,135 [Patent Document 2] US Patent No. 2021 / 0094761 Summary of the Invention [Problem to be solved by the invention]

[0006] The present disclosure focuses on a method and apparatus for stabilizing carrier baskets moving on a conveyor system, preferably at a loading / unloading station or in other areas of the conveyor system, to maintain the alignment of the baskets. It has now been found that at higher conveying speeds, the carrier baskets may wobble as they move around a return corner, for example, when approaching a loading station and / or an unloading station. This wobbles due to centrifugal forces acting on a pivotally supported carrier basket are undesirable and may result, for example, in the comb-like structure of the carrier basket formed by the carrier support fingers interfering with the support fingers or rollers of the loading / unloading station. The wobbles may also cause other undesirable contacts in areas with limited clearance along the path of the conveyor system, or may result in undesirable tipping or movement of the products in the carrier basket. [Means for solving the problem]

[0007] To address this, a carrier basket stabilization system is provided at least in the curved regions of the conveyor system.

[0008] In one aspect, the carrier basket stabilization system is configured for use with a conveyor system having a path over which vehicles are guided, with at least some of the vehicles having carrier baskets pivotally mounted thereon. The conveyor system includes a curved portion of the path, which may be, for example, immediately prior to at least one of a loading station or an unloading station. The carrier basket stabilization system includes a support configured to be disposed adjacent to the path. A deflectable element is disposed on the support, and the element extends generally parallel to the path with the element extending partially within a spatial envelope generated by the carrier basket as the carrier basket moves along the path. The deflectable element includes bristles configured to resist at least one of an inward or outward rocking motion of the carrier basket.

[0009] In one embodiment, the at least one deflectable element comprises first and second deflectable elements, and the first and second deflectable elements are disposed on opposite sides of the pathway. Preferably, the first and second deflectable elements are configured with respective upstream ends disposed at a carrier inlet side spaced further from the pathway than downstream ends disposed at a carrier basket outlet end of the carrier basket.

[0010] In one embodiment, the at least one deflectable element comprises a single deflectable element disposed along a curved portion of the path, and the deflectable element extends partially within a spatial envelope generated by the carrier basket as the carrier basket moves along the path.

[0011] In one embodiment, the bristles are arranged in one or more bristle segments attached to a support, each bristle segment having bristles held such that free ends of the bristles are arranged in a straight line. The bristle segments may be arranged at an angle to one another such that the straight free ends extend generally parallel to the curved portion. The number of bristle segments may vary, but is preferably at least two.

[0012] In another embodiment, a single bristle segment is provided.

[0013] In one particular configuration, the bristles include bristle ends that are aligned along a curved path that is parallel to the curved portion of the path, which may be formed as a single continuous bristle segment or multiple bristle segments.

[0014] Preferably, the support includes a curved surface that is generally parallel to and offset from the curved path of the bristle ends and acts as a non-deflectable limit stop against further outward rocking movement of the carrier basket.

[0015] In one embodiment, the bristles include an angled entrance region at the upstream bristle ends to provide graduated contact with the carrier basket.

[0016] In one preferred application, the curved portion of the path is disposed directly upstream of at least one of a loading station or an unloading station, and the bristles are configured to resist at least one of an inward or outward rocking motion of the carrier basket to maintain alignment of the carrier basket as it enters the loading or unloading station, preventing the comb-like structure of the carrier basket formed by the carrier support fingers from interfering with the support fingers or rollers of the loading / unloading station.

[0017] The present invention also provides a conveyor system including a carrier basket stabilization system having one or more of the configurations described herein.

[0018] In another aspect, a method of stabilizing carrier baskets moved on a conveyor system is provided, the conveyor system having a path over which vehicles are guided with at least some of the vehicles having carrier baskets pivotally mounted thereon, and the conveyor system including at least one of a loading station or an unloading station with a curved portion of the path disposed directly upstream of at least one of the loading station or the unloading station. The method includes the steps of (a) providing a support adjacent to the path, (b) providing a deflectable element on the support extending generally parallel to the path with the deflectable element extending partially within a spatial envelope generated by the carrier basket as it moves along the path, the deflectable element comprising bristles, and (c) the bristles restraining at least one of an inward or outward rocking motion of the carrier basket as it passes through the bristles.

[0019] The various aspects of the invention described herein may be used independently or together depending on the particular application. [Brief description of the drawings]

[0020] Further advantages of the present invention will become apparent from the following description of the embodiments taken in conjunction with the accompanying drawings. [Figure 1] 1 is a perspective view of Applicant's prior art conveyor system with which the present invention is utilized; FIG. [Diagram 2] FIG. 2 is an elevational view of the carrier basket stabilization system disclosed herein for use in connection with a conveyor system; [Diagram 3] FIG. 13 is a partial elevational view showing the carrier basket stabilization system with the carrier basket just exiting the stabilization system prior to passing through the loading station. [Figure 4] FIG. 13 is an elevational view of a second embodiment of a carrier basket stabilization system showing the carrier basket entering the upstream side of the deflectable element. [Diagram 5] FIG. 5 is an elevational view similar to FIG. 4 showing the carrier basket at an intermediate portion of the carrier basket stabilization system. [Figure 6] 6 is a view similar to FIGS. 4 and 5 showing the carrier basket as it exits the carrier basket stabilization system; FIG. [Figure 7] 5 is a perspective view showing a carrier basket moving through the carrier basket stabilization system of FIG. 4. [Figure 8] FIG. 8 is a perspective view of a portion of a conveyor system with which the carrier basket stabilization system of FIGS. 4-7 is utilized. [Figure 9] 9 is a side view of the carrier basket and carrier basket stabilization system taken along line 9-9 of FIG. 8. [Figure 10] FIG. 13 is an elevational view of a third embodiment of a carrier basket stabilization system, shown with the carrier basket entering the upstream side of the deflectable element. [Figure 11]FIG. 11 is an elevational view similar to FIG. 10 showing the carrier basket at an intermediate portion of the carrier basket stabilization system. [Figure 12] 12 is a view similar to FIGS. 10 and 11 showing the carrier basket as it exits the carrier basket stabilization system; FIG. [Figure 13] 11 is a perspective view showing a carrier basket moving through the carrier basket stabilization system of FIG. 10. FIG. [Figure 14] FIG. 14 is a perspective view of a portion of a conveyor system with which the carrier basket stabilization system of FIGS. 10-13 is utilized. [Figure 15] 15 is a side view of the carrier basket and carrier basket stabilization system taken along line 15-15 of FIG. 14. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Some terminology is used in the following description for convenience only and is non-limiting. The words "right", "left", "top" and "bottom" refer to directions in the drawings to which reference is made. The words "a" and "one", when used in the claims and in the corresponding parts of the specification, are defined to include one or more of the referenced articles, unless expressly stated otherwise. This term includes the words expressly mentioned above, their derivatives, and words of similar import. A list of two or more articles, e.g., "at least one" followed by "A, B, or C" means any individual one of A, B, or C, as well as any combination thereof. The terms about or approximately mean within ±10% of the specified value, unless otherwise stated, and within ±25° of the specified angle or direction, which also applies to linear segments that approximate curves.

[0022] FIG. 1 illustrates an embodiment of Applicant's conveyor system 10 from US 2021 / 0094761, which is incorporated herein by reference as if fully set forth. It includes a path 12 defined by a track 13 having one or more curved portions 14 and straight portions 15 along which a plurality of vehicles 20 are guided. A motor (22 in FIG. 8) drives the vehicles 20 along the track 13, either by directly coupling the vehicles 20 to each other or by having an intermediate section between the vehicles 20. Carrier baskets 30 are pivotally attached to at least some of the vehicles 20, with the carrier baskets 30 including carrier support fingers 32 cantilevered from the sides of the carrier baskets 30 pivotally connected to the vehicles 20. At least one of the loading station 40 or the unloading station 42 is disposed along the path 12, and as shown in FIG. 1, the curved portion 14 of the path 12 is disposed directly upstream of at least one of the loading station 40 or the unloading station 42. The loading station 40 and the unloading station 42 include support fingers 44 that are used to remove the articles conveyed from the carrier basket 30 by the carrier basket support fingers 32 that move between the loading station or unloading station support fingers 44 to pick up or drop off the articles conveyed by the conveyor system 10. As discussed in US 2021 / 0094761, the conveyor system 10 can provide increased flexibility in the design of the layout to suit specific applications and space requirements.

[0023] As mentioned above, the carrier baskets 30 may sway due to centrifugal forces as they move about their curved portions 14 of the path 12. This swaying of the carrier baskets 30 may be undesirable and may result, for example, in the carrier support fingers 32 of the carrier baskets 30 interfering with the support fingers 44 of the loading / unloading station that are used to remove the articles being conveyed from the carrier baskets 30 by the carrier basket support fingers 32 moving between the support fingers 44 of the loading or unloading station to pick up or drop off the articles being conveyed by the conveyor system 10. It may also result in a tipping or tilting movement of the packages being conveyed.

[0024] 2 and 3, a first embodiment of a carrier basket stabilization system 50 is illustrated. The carrier basket stabilization system 50 includes a support 52 configured to be disposed adjacent to the path 12, more preferably the curved portion 14 of the path 12. This may be at one or more locations along the path 12. A deflectable element 54 is disposed on the support 52 and extends generally parallel to the path 12, in this embodiment the curved portion 14 of the path 12. The deflectable element 54 extends partially within a spatial envelope S generated by at least the bottom edge of the carrier basket 30 as the carrier basket 30 moves along the path 12, and in this first embodiment along the curved portion 14. The deflectable element 54 includes bristles 56 configured to suppress outward rocking motion of the carrier basket 30. The bristles 56 may be in the form of nylon brush bristles or the like, or may be formed of other resiliently deflectable materials, and the term "bristles" is intended to encompass any plurality of parallel mounted, generally linearly extending resilient elements that are resiliently deflectable to absorb and resist outward rocking motion of the carrier basket 30 due to centrifugal forces as the carrier basket 30 moves along the path 12.

[0025] 2 and 3, bristles 56 include bristle ends 56A that are aligned along a curved path 60 that is parallel to curved portion 14 of path 12. Preferably, support 52 includes a curved surface 53 that is also parallel to, and offset from, the curved path 60 of bristle ends 56A and acts as a non-deflectable limit stop against further outward rocking motion of carrier basket 30.

[0026] 2, the bristle end 56A preferably includes an angled inlet region 57 upstream where the carrier basket 30 enters the carrier basket support and stabilization system 50. An additional angled outlet 59 may also be provided, as shown in FIGS. 2 and 3.

[0027] 4-9, a second embodiment of a carrier basket stabilization system 50' is illustrated, in which the bristles 56' are arranged in a plurality of bristle segments 58A'-58D' that are attached to a support 52' to form a deflectable element 54'. Each of the bristle segments 58A'-58D' has the bristles 56' held such that the free ends 56A' of the bristles 56' are arranged in a straight line (see path L), and the plurality of bristle segments 58A'-58D' are arranged at an angle to one another such that the straight-arranged bristle ends 56A' extend generally parallel to the curved portion 14 of the path 12. The bristle ends 56A' of adjacent ones of the bristle segments 58A'-58D' may slightly overlap as shown, or may be spaced apart. While the disclosed embodiment has four bristle segments 58A'-58D', one of ordinary skill in the art will appreciate that more or fewer bristle segments 58A'-58D' could be utilized depending on the particular application. Additionally, while the disclosed embodiment describes the bristle ends 56A' of the bristles 56 as being linearly arranged along a straight path L (as shown for each bristle segment 58A'-58D' in FIG. 4), it will be appreciated that these bristle segments 58A-58D could have the bristle ends 56A' arranged along a curved path to more closely approximate the curved portion 14 of the path 12. The deflectable element 54' defined by the bristles 56' extends partially within a spatial envelope S created by at least a bottom edge of the carrier basket 30 as the carrier basket 30 moves through the curved portion 14 of the path 12. And, although the bristles 56' are shown disposed on only one side of the path 12, the bristles could be disposed on both sides to prevent both inward and outward rocking of the carrier basket 30. Depending on the particular application, the bristles 56' could be disposed only on the inside of the path to prevent inward rocking.

[0028] As shown in Figures 7 and 9, a mounting bracket 62' may be utilized to connect the support 52' to the conveyor system 10. Alternatively, similar to the configuration shown in Figure 2, the support 52' may be mounted to the ground or from another surface adjacent the curved portion 14 of the path 12 defined by the conveyor system 10.

[0029] 10-15, a third embodiment of a carrier basket stabilization system 50″ is illustrated. Here, instead of one deflectable element as in the first and second embodiments, there are first and second deflectable elements 54A″ and 54B″, and the first and second deflectable elements 54A″ and 54B″ are disposed on opposite sides of the path. Each of the first and second deflectable elements 54A″ and 54B″ is attached to a respective support 52A″, 52B″. The bristles 56A″, 56B″ are illustrated with a straight configuration of the free ends 57A″, 57B″ of the bristles 56A″, 56B″. However, the free ends 57A″, 57B″ could have a curved path to more closely approximate the spatial envelope S generated by at least the bottom edge of the carrier basket 30 as the carrier basket moves along the path 12. The first and second deflectable elements 54A", 54B" are preferably positioned with their respective upstream ends spaced farther from the path 12 than the downstream ends of the elements. Although the disclosed embodiment has one deflectable element 54A", 54B" on each side of the path 12 with each of the deflectable elements 54A", 54B" formed as a single bristle segment, those skilled in the art will appreciate that more than one bristle segment may be utilized to form each of the first and second deflectable elements 54A", 54B", depending on the particular application. Here, the first and second deflectable elements 54A", 54B" are defined by bristles 56A", 56B", each element extending partially within a spatial envelope S created by at least a bottom edge of the carrier basket 30 as the carrier basket moves through the curved portion 14 of the path 12.

[0030] As shown in Figures 13-15, mounting brackets 62A", 62B" can be utilized to connect supports 52A", 52B" to conveyor system 10. Alternatively, similar to the configuration shown in Figure 2, supports 52A", 52B" may be mounted to the ground or from another surface adjacent to the path 12 defined by conveyor system 10, preferably in the area emerging from curved portion 14.

[0031] Also provided is a method of stabilizing a carrier basket 30 moved on a conveyor system 10 including a path 12 on which a vehicle 20 is guided, wherein supports 52, 52' are provided adjacent to a curved portion 14 of the path 12 and deflectable elements 54, 54' are disposed on the supports 52, 52' such that the deflectable elements 54, 54' extend generally parallel to the curved portion 14 of the path 12 with the deflectable elements 54, 54' extending partially within a spatial envelope S generated by the carrier basket 30 as the carrier basket moves through the curved portion 14 of the path 12. Here, the deflectable elements 54, 54' include bristles 56, 56' which may be arranged along a curved path 60 as described above or may be provided as a plurality of bristle segments 58A'-58D'. These bristles 56 , 56 ′ resist outward rocking motion of the carrier basket 30 as it moves through curved portions of the path 12 .

[0032] Those skilled in the art will appreciate that the stiffness of the bristles 56, 56' can be adjusted to suit a particular application, as can the spacing of the bristles 56, 56' from the curved portion 14 of the path 12. In a preferred embodiment, the bristles 56, 56' preferably extend at least about 2 inches from the supports 52, 52', and the spatial envelope S generated by the carrier basket 30 as it moves through the curved portion 14 of the path 12 preferably overlaps at least 0.5 to 1.0 inch of the bristle ends 56A, 56A' when the carrier basket 30 is suspended in a neutral position.

[0033] It will be appreciated that the above is presented merely by way of illustration, and not by way of any limitation. It is intended that various substitutions and modifications may be made to the described embodiment without departing from the spirit and scope of the present invention. Having thus described the present invention in detail, it will be appreciated and apparent to those skilled in the art that many physical modifications, only a few of which are mentioned in the detailed description of the present invention, may be made without changing the concepts and principles of the present invention embodied herein. It should also be appreciated that many embodiments are possible that incorporate only a portion of the preferred embodiment, without changing the concepts and principles of the present invention embodied herein, with respect to the elements. Thus, the present embodiment and any configurations should be considered in all respects as typical and / or illustrative, and not as limiting, and the scope of the present invention is indicated by the appended claims, and not by the above description, and therefore all alternatives and modifications of this embodiment that come within the meaning and range of equivalence of said claims should be embraced herein.

Claims

1. 1. A carrier basket stabilization system configured for use with a conveyor system having a path over which the vehicles are guided, with at least some of the vehicles having carrier baskets pivotally mounted on the vehicles, the path including a curved portion, the carrier basket stabilization system comprising: A support configured to be disposed adjacent to the pathway; at least one deflectable element disposed on the support and extending generally parallel to the path, the at least one deflectable element extending partially within a spatial envelope generated by the carrier basket as the carrier basket moves along the path; Equipped with A carrier basket stabilization system, wherein the deflectable element comprises bristles configured to resist at least one of inward or outward rocking motion of the carrier basket.

2. 2. The carrier basket stabilization system of claim 1, wherein the at least one deflectable element comprises first and second deflectable elements, and the first and second deflectable elements are disposed on opposite sides of the path.

3. 3. The carrier basket stabilization system of claim 2, wherein the first and second deflectable elements are positioned with their respective upstream ends spaced farther apart from the path than the downstream ends of the deflectable elements.

4. 2. The carrier basket stabilization system of claim 1, wherein the at least one deflectable element comprises a single deflectable element disposed along the curved portion of the path, and the deflectable element extends partially within a spatial envelope generated by the carrier basket as it moves along the path.

5. 2. The carrier basket stabilization system of claim 1, wherein the bristles are arranged in one or more bristle segments attached to the support, each of the bristle segments having the bristles held such that free ends of the bristles are arranged in a straight line.

6. 6. The carrier basket stabilization system of claim 5, wherein there are a plurality of said bristle segments disposed at an angle to one another such that said linearly disposed free ends extend generally parallel to said curved portion.

7. The carrier basket stabilization system of claim 1 , wherein said bristles include bristle ends aligned along a curved path that is parallel to said curved portion of said path.

8. The support is a curved surface parallel to and offset from the curved path of the bristle ends and acting as a non-deflectable limit stop against further outward pivoting movement of the carrier basket; 8. The carrier basket stabilization system of claim 7, comprising:

9. The carrier basket stabilization system of claim 7 , wherein said bristles include an angled entrance area upstream of said bristle ends.

10. 2. The carrier basket stabilization system of claim 1, wherein the conveyor system includes at least one of a loading station or an unloading station, the curved portion of the path is disposed directly upstream of the at least one of the loading station or the unloading station, and the bristles are configured to resist at least one of the inward or outward rocking motion of the carrier basket to maintain alignment of the carrier basket as the carrier basket enters the loading station or the unloading station.

11. A conveyor system including the carrier basket stabilization system of claim 1 .

12. 1. A method of stabilizing carrier baskets moved on a conveyor system having a path over which at least some of the vehicles are guided, with the carrier baskets pivotally mounted on the vehicles, the conveyor system including at least one of a loading station or an unloading station, with a curved portion of the path disposed directly upstream of at least one of the loading station or the unloading station, the method comprising: providing a support adjacent the pathway; providing a deflectable element on the support, the deflectable element extending generally parallel to the path with the deflectable element extending partially within a spatial envelope generated by the carrier basket as the carrier basket moves along the path, the deflectable element including bristles; Including, The method of claim 1, wherein the bristles restrain at least one of an inward or outward rocking motion of the carrier basket as the carrier basket passes through the bristles.

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