Pendulum conveyor

Abstract

A conveyor system is disclosed that includes a tray suspended from above by two or more vertical support parts. The tray travels in the positive direction from the uppermost point of the tray to the lowermost point of the tray. The system includes a one-way continuous rotation input mechanism. In the first stage of a single rotation cycle, the tray is moved in the reverse direction towards the uppermost point by the input mechanism. In the second stage of a single rotation cycle, the tray freely falls in the positive direction without restriction by the input mechanism. The system includes a bumper arranged to suddenly stop the tray when the tray travels in the positive direction. Due to the sudden stop, the tray bounces back in the reverse direction, and the material being conveyed located on the tray continues to travel in the positive direction by the forward propulsion force of the material being conveyed.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims the priority of U.S. Provisional Patent Application No. 63 / 357,708, filed on July 1, 2022, and all of its content is incorporated herein by reference.

[0002] The present disclosure generally relates to pendulum conveyors, and more particularly to improved pendulum conveyors that use kinetic energy to move various materials.

Background Art

[0003] Conveyor systems are generally mechanical equipment used in industrial environments to move products and materials from one location to another. Conveyor systems are known to be used in businesses that handle items such as heavy machinery, mass - produced products, and raw materials. Conveyor systems are used in various industries and come in various shapes, sizes, and operating systems depending on the requirements of a particular business.

[0004] One known conveyor system is a vibrating conveyor, including a reciprocating conveyor or a vibrating conveyor. A vibrating conveyor is of a type that bounces products on a conveying member along the path of the conveyor system and moves materials on a conveying member that can be, for example, in the shape of a trough. Such a system generates a vibration force in the direction and at an angle of the desired path of the material on the conveying member. The material is physically lifted from the conveying member by the vibration force and pushed or moved forward.

[0005] However, conventional conveyor systems are difficult to control. When the vibration speed is exceeded, harmful friction occurs in the conveyor system, causing stress that is detrimental to its components, which may shorten the system's lifespan. Furthermore, reciprocating conveyors and vibrating conveyors usually require regular maintenance due to the nature of the stress exerted on at least some of the conveyor system's components and the friction generated by the operating system's drive mechanism. Replacing or maintaining worn belts or other mechanisms within the system is costly and time-consuming, and may require the system to be stopped for extended periods for maintenance and repair.

[0006] Some known systems use pneumatic control systems or actuators that include a transport tray supported by a housing. The drive system linearly drives the transport tray to advance the material supported by the transport tray along the length of the tray. Another known system operates using a rotatable cam surface and a cam follower that provides reciprocating motion in one direction and uses a counterweight to operate in the opposite direction. The cam causes motion in one direction, and the counterweight causes motion in the opposite direction. These are some examples of known systems.

[0007] Generally, these systems and other systems operate based on principles that distinguish between static and kinetic friction. Since the coefficient of static friction is typically higher than the coefficient of kinetic friction, an object tends to stay in place while static friction is overcome while it is moving, and then, while the object is moving relative to the tray, sliding occurs because the kinetic friction is low. These systems may rely on complex mechanical devices where sudden forward and subsequent backward movements occur, which can cause excessive wear on the system, leading to wear, damage, and costly and time-consuming repairs. Costs are incurred not only by the time spent repairing the machinery but also by the downtime when the product is not moving within the facility.

[0008] Therefore, an improved material handling system is needed. SUMMARY OF THE INVENTION

Problems to be Solved by the Invention

[0009] The present disclosure relates to a system and method for transporting materials on a pendulum conveyor.

Means for Solving the Problems

[0010] In one aspect, the conveyor system includes a tray supported from above or suspended by two or more vertical supports, the tray traveling in a positive direction from the uppermost point of the tray to the lowermost point of the tray. The system includes a one-way continuous rotation input mechanism that moves the tray in the reverse direction to the uppermost point of the tray in the first stage of a single rotation cycle, and freely drops the tray in the positive direction without limitation in the second rotation cycle (the second stage of a single rotation cycle). The one-way continuous rotation input mechanism is a single-speed motor having a constant rotational speed per minute. The system includes a bumper arranged to suddenly stop the tray when the tray travels in the positive direction, such that the tray rebounds and travels in the reverse direction while the material to be conveyed located on the tray continues to travel in the positive direction by the propulsive force of the material to be conveyed forward.

[0011] In another aspect, the material conveying method includes moving the tray in the reverse direction in the first stage of the rotation cycle, releasing the tray by freely dropping it in the positive direction without limitation in the second stage of the rotation cycle, suddenly stopping the tray by a bumper when the tray travels in the positive direction, and rebounding the tray in the reverse direction such that the material to be conveyed on the tray continues to travel in the positive direction by the propulsive force of the material to be conveyed forward.

[0012] Various other features and advantages will become apparent from the following detailed description and drawings. For example, it will become apparent from the present disclosure that the disclosed system and method can be used in various other contexts including different input mechanisms, conveyor systems of different sizes, and the movement of various materials to be conveyed.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3A

Figure 3B

Figure 3C

Figure 3D

Figure 4

Figure 5

Figure 6

Figure 7A

Figure 7B

Figure 8

Figure 9

Figure 10

Figure 11A

Figure 11B

Figure 12A

Figure 12B

Figure 12C

[0014] With reference to the following description and drawings, exemplary approaches to the disclosed systems and methods will be described in detail. The drawings represent several possible approaches, but are not necessarily to scale, and certain features may be exaggerated, deleted, or partially sectioned to better illustrate and describe the present disclosure. Further, the descriptions set forth herein are not exhaustive and do not limit or restrict the claims to the exact forms and configurations shown in the drawings and disclosed in the following embodiments for carrying out the invention.

[0015] The present disclosure generally relates to a pendulum conveyor system for moving a material to be conveyed along a tray. An exemplary conveyor system includes a tray supported or suspended from above by two or more vertical supports, the tray traveling in a positive direction from the uppermost point of the tray to the lowermost point of the tray. A one-way continuous rotation input mechanism operates to move the tray in a reverse direction opposite to the first direction (positive direction) to the uppermost point of the tray in the first stage of a single rotation cycle. In the second stage of a single rotation cycle, the system allows the tray to freely fall in the positive direction without restriction. The one-way continuous rotation input mechanism includes a single-speed motor that rotates at a constant rotational speed per minute. The bumper is arranged to suddenly stop the tray when the tray travels in the positive direction such that the tray bounces back and travels in the reverse direction while the material to be conveyed located on the tray continues to travel in the positive direction by a propulsive force in front of the material to be conveyed.

[0016] Referring to the drawings, as schematically shown in FIGS. 1-8, the conveyor system 2 includes a tray 4 suspended from above by two or more vertical supports 6, and these vertical supports 6 themselves are suspended from a fixed upper position 7 which can be, for example, a support bracket or attachment to a ceiling, wall, or floor. By suspending the vertical supports 6 from above, the tray 4 travels in the reverse direction 32 to the uppermost point 36 of the tray, and then travels in the forward direction 40 downward 42 to the lowermost point of the tray 4. The conveyor system 2 includes a one-way continuous rotation input mechanism 8 (or simply input mechanism 8), and in one stage 34 (FIG. 3A) of a single rotation cycle, the input mechanism moves the tray 4 in the reverse direction 32 opposite to the forward direction 40 upward 36 to the uppermost point of the tray 4. In another stage 38 (FIG. 3C) of a single rotation cycle, the one-way continuous rotation input mechanism 8 allows the tray 4 to freely fall downward 42 and in the forward direction 40 without restriction. The forward 40 and reverse 32 movements of the tray 4 are generated by the flexibility of the vertical supports 6, which in one example are flexible straps made of a sturdy cloth or other material that allow the tray 4 to swing, such as flexible metal bars that bend forward and backward, or ropes reinforced with steel. Thus, generally, "freely fall without restriction" means that the tray 4 swings forward by gravity as if it were riding on a rope or other device that does not impede its movement. Freely fall without restriction means that the tray 4 is supported by a flexible metal bar or other material that bends in the elastic region when pulled in one direction, for example, and offers some resistance to movement, and when the tray is released, it moves forward not only by gravity but also by finally returning to an unrestrained and unbent position.

[0017] The conveyor system 2 includes a bumper 10 arranged to suddenly stop the tray 4 when the tray 4 travels in the forward direction 40, such that when the tray 4 travels in the forward direction 40, the tray 4 bounces back and travels in the reverse direction 32, and the material 12 to be conveyed located on the tray 4 continues to travel in the forward direction 40 by the forward propulsion force of the material 12 to be conveyed. In one example, the bumper 10 is connected to a support structure or other rigid attachment within the conveyor system 2 (as shown in FIG. 5), or, for example, the bumper 10 may be completely separated from the conveyor system 2 and rigidly attached in place and attached to the floor.

[0018] In one example, as shown in FIG. 4, the vertical support 6 is arranged to prevent the tray 4 from swaying laterally due to the expanded shape or "V" shape of the vertical support 6. Such prevention is shown in FIG. 4, where an angle X extending generally along the length of each vertical support 6 forms a "V", thereby preventing the tray 4 from swaying left and right. Thereby, the tray 4 sways back and forth from the vertical support 6, the V-shaped arrangement of the vertical support 6 prevents left and right movement, and if the movement of the tray 4 is not restricted by the bumper 10, the tray 4 continues to sway back and forth and finally stops. In one example, the angle X is about 30 degrees, but is not limited to this angle, and in other examples, the vertical support 6 may be arranged vertically without being in a "V" shape.

[0019] The one-way continuous rotation input mechanism 8 includes a continuous rotation single-speed motor 14 (Fig. 6) and a one-way bearing 16. The single-speed motor 14 operates at a constant speed so that the continuous rotation input mechanism 8 rotates at a constant rotational speed per minute. The one-way bearing 16 is, in one example, a sprag bearing 18 (shown in Figs. 7A and 7B), but may be other one-way mechanisms such as a cam 20 (Fig. 9) and a follower 22 mechanism. The single-speed motor 14 of the one-way continuous rotation input mechanism 8 is coupled to the tray 4. The single-speed motor 14 is connected to the one-way bearing 16 via a shaft 17. When the one-way bearing 16 is disposed within the first pulley wheel 24, the pulley wheel 24 rotates together with the one-way bearing 16. When the first pulley wheel 24 is connected to the second pulley wheel 24' via a belt 26, the first pulley wheel 24 and the second pulley wheel 24' rotate relative to each other. When a drive arm or connecting rod 28 is connected to the second pulley wheel 24', when the second pulley wheel 24' rotates, the drive arm 28 and the tray 4 connected to the drive arm 28 move in the reverse direction 32 and the forward direction 40. In the illustrated example, in one example, by arranging the bumper 10 beyond the lowest point 42 of the tray, the tray 4 is configured to travel to and pass through the lowest point 42 of the tray. In another example, the bumper 10 is arranged before passing through the lowest point 42 of the tray (not shown).

[0020] In one example, the tray 4 is a trough including side walls 30. By including the side walls 30, it is possible to avoid the conveyed material 12 inadvertently moving laterally and falling from the side of the tray 4, or to prevent the conveyed material from falling from the side when it is dropped or placed on the tray 4. The conveyor system 2 may include at least one second tray 4' supported by two or more vertical supports 6, as shown in FIG. 8, and the tray 4 and the second tray 4' are coupled to each other. The second tray 4' may be coupled to the first tray 4 by a rigid connection or loosely coupled to the first tray 4 via a hook or bracket 29. Thereby, the second tray 4' moves with the first tray 4 by the hook 29, and the second tray 4' travels to the lowest point 42 of the tray at a shorter distance than the first tray 4 and collides with the bumper 10 earlier than the first tray 4. However, due to the coupling via the hook or bracket 29, the second tray 4' can move slightly backward by an axial coupling. However, since there is not so much a large gap between the tray 4 and the tray 4', it is possible to avoid the conveyed material 12 falling between the tray 4 and the tray 4'. Therefore, the tray 4 and the tray 4' can push against each other until the tray 4 encounters the bumper 10, and the hook 29 allows it to move further forward until it encounters the bumper 10'. In this way, during operation, when the first tray 4 swings downward and collides with its bumper 10, and then the second tray 4' collides with its bumper 10', interference between the two operations is avoided.

[0021] A method of conveying a material 12 in a conveyor system 2 includes moving a tray 4 in a reverse direction 32 in a first stage 34 of a rotation cycle, the tray 4 being configured to move by a one-way continuous rotation input mechanism 8. The system 2 (the method) includes releasing the tray 4 by allowing it to freely fall without restriction in a forward direction 40 in a second stage 38 of the rotation cycle. The system 2 includes rapidly stopping the tray 4 by a bumper 10 when the tray 4 travels in the forward direction 40. The system 2 includes rebounding the tray 4 in the reverse direction 32 such that the conveyed material 12 on the tray 4 continues to travel in the forward direction 40 by a propulsive force of the conveyed material 12 forward. The system 2 includes suspending the tray 4 from two or more vertical supports 6. The system 2 includes oscillating the tray 4 from two or more vertical supports 6. The system 2 includes a drive arm 28 (FIG. 10) coupled to the one-way continuous rotation input mechanism 8 from the tray 4.

[0022] As shown in FIG. 1, the conveyor system 2 includes a tray 4 that moves a conveyed material 12. The conveyed material 12 travels along an upper surface of the tray 4. The materials 12 differ in shape, size, and weight. In one example, the tray 4 is a horizontal plane, but may be a trough that includes side walls that hold the material 12 on the tray 4. The tray 4 is supported by two or more vertical supports 6.

[0023] For example, a small tray may include two vertical supports on either side of a first end of the tray. A larger tray may include several pairs of vertical supports arranged along the length of the tray. Generally, for optimal load distribution and operation, it is desirable to include 2, 4, 6, 8, or more even numbers of vertical supports 6, but in some examples, an odd number of vertical supports 6 may be used. The minimum number required for operation is 2, and it is understood that a smaller or more compact design may perhaps be used. If there are vertical supports on either side of the tray 4, there may be a basic back-and-forth oscillation of the tray 4.

[0024] When the tray 4 is supported by the vertical support 6, the tray 4 is suspended from the vertical support 6 and swings. In one example, the vertical support 6 is supported by a fixed upper position 7 (such as a floor frame, an overhead ceiling, or a support structure), and is a flexible strap attached to the tray 4 by a support bar 13. As a result, the tray 4 swings and travels from the tray uppermost point 36, and then returns to the tray lowermost point 42 near the position where it encounters the bumper 10. The strap may be a flexible cloth, a rope, or a metal piece that bends when swinging. Further, the strap may be made of other materials such as leather or polymer.

[0025] In the system 2, a bumper 10, which is rubber in one example, is attached. Further, the bumper 10 may be another material including but not limited to other polymer compositions such as polypropylene or urethane. Such materials operate in the elastic region and are temporarily deformed by a collision. The bumper 10 is arranged such that the tray 4 travels to the tray lowermost point 42 before the tray 4 collides with the bumper 10 and / or passes through the tray lowermost point 42. (As shown in FIG. 1) The bumper 10 is attached to the bumper support 11. In one example, the bumper support 11 may be separate from the frame.

[0026] In other words, as shown in FIG. 8, the bumper 10 may contact the tray 4 with one of the support bars 13 as shown, or may be fixedly attached to the tray 4 and contact the tray 4 at a position separate from the support bar 13. In the illustrated example, one of the support bars 13 is used to support one of the vertical supports 6 and also serves double as a convenient location for contact with the bumper 10. The bumper 10 prevents further travel of the tray 4 in the forward direction 40 and bounces the tray 4 back to travel in the reverse direction 32. The material 12 being conveyed on the tray 4 continues to move in the forward direction 40 by the propulsive force in front of the material 12 being conveyed.

[0027] A drive arm 28 coupled to the unidirectional continuous rotation input mechanism 8 is attached to the tray 4. By connecting the drive arm 28 to the tray 4, the rotation from the input mechanism 8 moves the tray 4 in the reverse direction 32 in the first stage 34 of a single rotation cycle shown in FIG. 3B. Due to the weight of the tray 4, the rotation speed of the one-way bearing 16 increases, enabling free fall without restriction in the forward direction 40 in the second stage 3 of a single rotation cycle shown in FIG. 3C.

[0028] The unidirectional continuous rotation input mechanism 8 includes a continuously rotating single-speed motor 14 and a one-way bearing 16. In the illustrated example, the one-way bearing 16 is a sprag bearing 18, but is not limited to the sprag bearing 18, and may be, for example, a cam 20 and follower 22 mechanism as shown in FIG. 9. In the illustrated example, the one-way bearing 16 is separate from the continuously rotating single-speed motor 14. The one-way bearing 16 is connected to the continuously rotating single-speed motor 14 via a shaft 17. The one-way bearing 16 is incorporated into the first pulley wheel 24. The first pulley wheel 24 is coupled to the second pulley wheel 24' via a belt 26.

[0029] In an example, as shown in FIG. 1, the unidirectional continuous rotation input mechanism 8 may be electrically connected to the controller 62, and the controller 62 may be further connected to the computer 60. For example, the input mechanism 8 may be directly connected to the controller 62 via a wired connector, or may be connected to the controller 62 via, for example, Bluetooth or other wireless connections. The controller 62 and the computer 60 can be used for operation management, control, or maintenance of the conveyor system 2, such as supplying power to the motor 14, recording data from the sensor 1018 (as described below with reference to FIG. 11A), or maintaining a maintenance and usage schedule. According to the present disclosure, it is assumed that the controller 62 and the computer 60 may not be included and the input mechanism 8 may be manually controlled.

[0030] Figure 2 is a flowchart of the operation steps 100 shown in FIGS. 3A to 3D. FIGS. 3A to 3D generally show the operation steps 100, and the relative distances between components may not be to scale. Illustrations of positions such as the tray uppermost point 36 and the tray lowermost point 40 are simplified for ease of understanding and may not be to scale. In step 102 corresponding to FIG. 3A, the one-way continuous rotation input mechanism 8 is engaged. The single-speed motor 14 engages and begins to rotate at a constant rotational speed per minute.

[0031] The illustrations in FIGS. 3A to 3D represent one complete cycle and show any arbitrary start and end of the cycle for the sole purpose of explanation and discussion. For example, FIGS. 3A and 3D both show the conveyor system 2 in the same configuration, but in FIG. 3D, the material being conveyed 12 moves to a new position 15. Again, note that the drawings are not to scale. For the sake of explanation, it should be understood that in FIGS. 1, 3A, 3B, 3C, and 3D, the fixed upper position 7, the bumper 10, the bumper support 11, and the one-way continuous rotation input mechanism 8 are all arranged in the same relative positions for each figure. During the operation of the one-way continuous rotation input mechanism 8, the tray 4 moves relative to the bumper 10, and as the tray 4 undergoes the described movement, one of the support bars 13 collides with the bumper 10, the direction of the tray 4 changes abruptly as described in this specification, and the material being conveyed 12 moves to a new position 15.

[0032] In step 104, corresponding to FIG. 3B, the tray 4 begins to travel in the reverse direction 32 to the tray uppermost point 36 reached in the first stage 34 of a single rotation cycle. The single-speed motor 14 transmits rotational motion to the one-way bearing 16 via the shaft 17. The one-way bearing 16 rotates the second pulley wheel 24' via the belt 26 in order to rotate the first pulley wheel 24. By connecting the second pulley wheel 24' to the tray 4 with the drive arm 28, the tray 4 moves rearward and upward in the first stage 34 of the rotation cycle. In the first stage 34, the motor 14 and the one-way bearing 16 are directly coupled and rotate at approximately the same speed.

[0033] In step 106, corresponding to FIG. 3C (shown at the end of the free fall of tray 4), the second stage 38 of a single rotation cycle occurs. When reaching the uppermost point 36 of tray 4 at the end of step 104, slippage occurs at the sprag bearing 18 and free fall begins. Due to the weight of tray 4, the sprag bearing 18 moves, increasing the rotational speed of the sprag bearing beyond the rotational speed of motor 14, enabling tray 4 to freely fall forward and downward towards the tray lowermost point 42.

[0034] At the end of the free fall, tray 4 contacts bumper 10, rapidly decelerating tray 4. Tray 4 loses its forward driving force, but since the material to be conveyed 12 still has a forward driving force, material 12 overcomes static friction and continues to travel in the forward direction 40. Tray 4 bounces back in the reverse direction 32 from bumper 10 before the drive arm 28 and the input mechanism 8 are re-engaged, thereby driving tray 4 in the reverse direction 32 to restart the rotation cycle.

[0035] Step 102 and FIG. 3A show a one-way continuous rotation input mechanism 8, which engages such that the motor 14 and the one-way bearing 16 rotate. By coupling the drive arm 28 from tray 4 to the input mechanism 8, tray 4 travels along with the motion generated from the input mechanism 8.

[0036] Steps 104 and FIG. 3B show the input mechanism 8 in the first stage 34 of the rotation cycle. In the first stage 34 of the rotation cycle, the input mechanism 8 moves tray 4 in the reverse direction 32 by the drive arm 28, the pulley wheels 24, 24', the belt 26, the one-way bearing 16, the shaft 17, and the motor 14. The material to be conveyed 12 is located on tray 4 and cannot overcome static friction, so it is held at a predetermined position on tray 4. The vertical support 6 swings together with tray 4. The input mechanism 8 has already moved tray 4 backward and upward to the tray uppermost point 36 by the motor 14 and the one-way bearing 16. From this position, the input mechanism 8 starts the second stage 38 of the rotation cycle.

[0037] In step 106 and in Figure 3C, the input mechanism is in the second stage 38 of the rotation cycle. Due to the weight of the tray 4, the rotation speed of the one-way bearing 16 increases, and the tray 4 freely falls without restriction. The tray 4 travels in the positive direction 40 towards the tray lowest point 42. When the tray 4 contacts the bumper 10, the tray 4 that is traveling forward rapidly decelerates, and the tray 4 bounces back in the reverse direction 32. Since the forward propulsive force of the material 12 to be conveyed continues during the collision, the material 12 continues to move in the positive direction 40.

[0038] In step 108 and in Figure 3D, the material 12 to be conveyed overcomes static friction by the forward propulsive force of the material 12 to be conveyed and advances to a new position 15 on the tray 4. Figure 3D shows the new position 15 of the material 12 to be conveyed when a single rotation cycle of the input mechanism 8 starts again.

[0039] Figure 4 shows a rear view of the conveyor system 2 and the one-way continuous rotation input mechanism 8 coupled to the tray 4. The input mechanism 8 includes a single-speed motor 14, a shaft 17, a one-way bearing 16, pulley wheels 24, 24', and a belt 26. The one-way bearing 16 is coupled to the tray 4 via a drive arm 28, a pulley wheel 24', and a belt 26. By connecting the motor 14 and the bearing 16 via the shaft 17, the rotational movement from the motor 14 is provided to the bearing 16. The one-way bearing 16 is illustrated as having a sprag bearing 18, but may be another mechanism such as a cam 20 and a follower 22 mechanism (shown in Figure 9). The sprag bearing 18 is incorporated into the first pulley wheel 24. The first pulley wheel 24 is connected to the second pulley wheel 24' via a belt 26. The second pulley wheel 24' rotates together with a crank journal 19, also called a crank pivot or a crank arm surface, attached to the end of the drive arm 28. By connecting the drive arm 28 to the tray 4 at the crank journal 19, the movement is transmitted from the tray 4 to the one-way bearing 16, and vice versa.

[0040] During operation, the motor 14 rotates at a single speed. In the first stage 34 of a single rotation cycle, the motor 14 rotates at approximately the same speed as the sprag bearing 18. The sprag bearing 18 drives the tray 4 rearward and upward by means of the pulley wheels 24, 24', the belt 26, the crank journal 19, and the drive arm 28. In the second stage 38 of a single rotation cycle, the weight of the tray 4 moves the drive arm 28. Since the sprag bearing 18 can rotate ahead of the motor 14 due to the weight of the tray 4, the tray 4 freely falls forward. The rotation of the sprag bearing 18, whose rotation speed increases, is transmitted to the tray 4 by the pulley wheels 24, 24', the belt 26, and the drive arm 28, causing the tray 4 to freely fall. At the end of the second stage 38 of a single rotation cycle, when the tray 4 contacts the bumper 10, the tray 4 decelerates and rebounds in the reverse direction 32. The sprag bearing 18 decelerates to the speed of the motor 14 and is driven by the motor 14 in the first stage 34 of the next rotation cycle.

[0041] It should be noted again that, as particularly shown in FIGS. 1 and 3A - 3D, the drawings are not to scale and are included for illustrative purposes, for example, by showing various aspects of the drawings to an extent that may overly exaggerate the movement of the tray 4. This is to clearly explain the case where the tray 4 is pulled back from the bumper 10 in FIG. 3A, FIG. 3B shows the case where the bumper 10 is further pulled back, FIG. 3C shows the case where the support bar 13 engages with the bumper 10, and FIG. 3D shows the case where the material 12 moves to the position 15 by its forward propulsion force and the case where the tray 4 is pulled back from the bumper 10 again as the next cycle progresses. The fixed elements 7, the bumper 10, and the input mechanism 8 are in the same relative positions for each figure, and through the periodic operation, the operations disclosed in this specification are realized, whereby the material 12 moves forward.

[0042] FIG. 5 shows a perspective view of a tray 4 suspended from an upper position 7 by a vertical support portion 6. The tray 4 is a trough having side walls 30 that prevent the material 12 being conveyed from falling out of the tray 4 by potential horizontal movement. In the illustrated example, the tray 4 is suspended from above by four vertical support portions 6, two of which are on either side of the tray 4 (only three vertical support portions are shown in the figure).

[0043] FIG. 6 is a side view of a one-way continuous rotation input mechanism 8 coupled to the tray 4. The input mechanism 8 includes a one-way bearing 16. The one-way bearing 16 is a sprag bearing 18, but may be another mechanism such as a cam 20 and a follower 22 mechanism as shown in FIG. 9. The one-way bearing 16 is configured to include operations in a first stage 34 and a second stage 38 of a single rotation cycle showing a driving motion in the reverse direction 32 and a free fall motion in the forward direction 40. The one-way bearing 16 is coupled to the motor 14 via a shaft 17. The sprag bearing 18 is incorporated into a pulley wheel 24 coupled to a second pulley wheel 24' via a belt 26. Since the second pulley wheel 24' is coupled to the drive arm 28 via a crank journal 19, the sprag bearing 18 and the drive arm 28 can move together by the pulley wheels 24, 24', and the belt 26. Since the one-way bearing 16 is indirectly coupled to the tray 4 via the drive arm 28, the tray 4 travels in the free fall forward direction 40 and the drive reverse direction 32 by the one-way bearing 16.

[0044] As shown in FIGS. 4 and 5, the vertical support portion 6 is suspended from a fixed upper position 7 illustrated as a support bracket. The upper position 7 may be a ceiling as another example. By suspending the vertical support portion 6 from the fixed upper position 7, the tray 4 travels in the positive direction 40 from the tray uppermost point 36 to the tray lowermost point 42 during the operation of the system. The vertical support portion 6 is arranged to prevent the tray 4 from swaying laterally due to the widened shape or "V" shape of the vertical support portion 6 formed by the angle X. In one example, the vertical support portion 6 is suspended straight. In one example, the vertical support portion 6 is a flexible strap supported by the fixed upper position 7 and attached to the tray 4 by a support bar 13, allowing the tray 4 to swing and travel from the tray uppermost point 36 to the tray lowermost point 42. The strap may be a flexible cloth, rope, or a metal piece that bends when swinging. Further, the strap may be other materials such as leather or polymer.

[0045] FIGS. 7A and 7B show an example where the one-way bearing 16 is a sprag bearing 18. The sprag bearing 18 is a one-way clutch having a non-rotating asymmetric figure-eight sprag 44 or other elements that allow one-way rotation. In the first rotation direction, as the sprag 44 slides, the one-way bearing 16 rotates in a free-wheel motion. In the second opposite direction, when torque is applied, the sprag 44 tilts slightly and is sandwiched between the walls of the bearing and restrained by friction. Due to the backstopping action by the sandwiching, the one-way bearing 16 is maintained as a one-way mechanism.

[0046] Tray 4 may have various lengths to convey material 12 as needed. Further, at least two trays 4, 4' may be joined to create a longer system 2. As shown in FIG. 8, the first tray 4 is supported from above by two or more vertical supports 6 and an upper position 7. The vertical supports 6 are connected to the tray 4 by support bars 13. At the end of the first tray 4, a second tray 4' is joined, which is supported by two or more vertical supports 6 and optionally has its own bumper 10' and support bar 13'. The first tray 4 and the second tray 4' are arranged to contact the first bumper 10 and the second bumper 10', respectively. The second tray 4' is rigidly joined to the first tray 4 so that it travels with the first tray 4 when the first tray 4 moves in the reverse direction 32 in the first stage 34 of the rotation cycle by a one-way continuous rotation input mechanism 8. The second tray 4' may be loosely joined to the first tray 4, whereby the second tray 4' collides with the second bumper 10' before the first tray 4 collides with the first bumper 10 and is configured to travel in the forward direction 40 over a shorter distance than the first tray 4. The arrangement in the loosely joined system 2 is such that the first tray 4 and the second tray 4' do not collide with each other and the system 2 operates or stays separated from each other. Thus, during operation, when the first tray 4 swings downward and collides with its bumper, and then immediately the second tray 4' collides with its bumper, the two operations are prevented from interfering with each other, and the first tray 4 and at least the second tray 4' may be joined by welding, a hook mechanism 29, or other connections. Each additional tray to the system is supported by two or more vertical supports and includes a bumper.

[0047] FIG. 9 shows an embodiment including a cam 20 and a follower 22 mechanism. As shown in the figure, the tray 4 is coupled to the follower 22 and moves with the follower 22. The follower maintains contact with the cam 20. The cam 20 is offset from the center and is in the shape of a catapult. The cam 20 is coupled to the second pulley wheel 24'. The single-speed motor 14 is coupled to the first pulley wheel 24. As the belt 26 rotates around the first and second pulley wheels 24, 24', the motion from the motor 14 is transmitted to the cam 20 by the belt 26 and the pulley wheels 24, 24'. As the cam 20 rotates, the follower 22 reciprocates according to the shape of the cam 20. Motion is generated by the shape of the cam 20, and as a result, generally the tray 4 and the follower 22 move in the reverse direction 32 in the first stage 34 of the rotation cycle and free-fall in the forward direction 40 in the second stage 38 of the rotation cycle.

[0048] Figure 10 shows an embodiment in which the drive arm 28 is a self-compensating connecting rod 1000. The self-compensating connecting rod 1000 includes a solid longitudinal portion 1004 with a crank bearing 1002 disposed at a first end. Since the crank bearing 1002 is configured to be attached to the crank journal 19, the self-compensating connecting rod 1000 can move together with the pulley wheels 24, 24' and the belt 26 when attached to the crank journal 19 (see other figures). The longitudinal portion 1004 is connected to a cylinder 1006 at a second end opposite the first end and the crank bearing 1002. The piston 1008 can slide back and forth within the cylinder 1006 by being partially disposed within the cylinder 1006. It is envisioned that the element 1006 need not be cylindrical and can be of other shapes such as circular, rectangular, square, etc. As the piston 1008 moves within the cylinder 1006, no additional stress is applied to the crank journal 19 and the longitudinal portion 1004 when the drive arm 28 moves together with the pulley wheels 24, 24'. A spring 1010, or a pair of springs 1010, 1010' is at least partially disposed at an end of the cylinder 1006 opposite the longitudinal portion 1004. The springs 1010, 1010' are arranged to interact with the piston 1008 as the piston 1008 slides back and forth within the cylinder 1006. The springs 1010, 1010' reduce the impact load by the driving force of the movement from the longitudinal portion 1004 and the crank bearing 1002 when the piston 1008 slides within the cylinder 1006. A stop tube 1012 is disposed either inside or outside the axial direction of the springs 1010, 1010' (shown to be disposed outside) to prevent excessive compression of the springs 1010, 1010'. In one example, the spring 1010 may be a single spring or a pair of springs 1010, 1010' (such as a clam shell of "elastic" material closed outside the piston 1008). Similarly, the stop tube 1012 may be a single part attached around the springs 1010, 1010' or a plurality of clam shell parts 1012 / 1012'.The piston 1008 includes a connection point or interface 1017 with a piston rod 1014 that extends from an end of the piston 1008 and at least a portion of which extends outside the cylinder 1006. The piston rod 1014 is connected to a bracket 1019 by at least one flexible element 1016. By connecting the bracket 1019 to the self-compensating connecting rod 1000 to the tray 4, the movement of the self-compensating connecting rod 1000 can move the tray 4 as described in detail above. In this embodiment and other embodiments disclosed herein, the flexible element 1016 allows the piston rod 1014 to pivot between the bracket 1019 by connecting the piston rod 1014 to the bracket 1019, thereby eliminating the need for lubrication between components and reducing the required maintenance and mechanical wear of the components.

[0049] As shown in FIGS. 11A, 11B, 12A, 12B, and 12C, the system 2 is shown to have two or more trays 4, 4'. FIG. 11A shows the entire system having a plurality of trays 4, 4', and FIG. 11B shows enlarged views of two of the trays 4, 4' of FIG. 11A. FIG. 12A shows a top view of the bumper collision cross beam 1025 and related assembly components also related to FIGS. 11A and 11B. FIG. 12B shows a side view of the bumper collision cross beam 1025 and related assembly components also related to FIGS. 11A and 11B. FIG. 12C shows a front view of the bumper collision cross beam 1025 and related assembly components also related to FIGS. 11A and 11B.

[0050] As shown in these figures, elements common to the above figures are indicated by the same reference numerals where appropriate. However, in the illustrations related to FIGS. 11A, 11B, 12A, 12B, and 12C, the rotary input mechanism 8 includes a drive arm 28 attached to a connecting rod interface bracket 1024, and the connecting rod interface bracket 1024 is directly connected to a bumper collision cross beam 1025, and the bumper collision cross beam 1025 is connected to a tray support portion 1026 of the leftmost tray 4. The tray support portion 1026 is generally attached to either side of the tray 4 and is directly connected to the bumper collision cross beam 1025 or the non-bumper collision cross beam 1029 from tray to tray. The illustrated assembly includes two support structures 1027 (seen in the side views of FIGS. 11A and 11B) that extend axially along the assembly and are also shown in the top view of FIG. 12A. In the case of a tray with a support structure 1027 provided between the support bars 13, a bumper 10 supported by a fixed bumper mount 1020 spanning the support structure 1027 is also included, as seen in FIGS. 12A and 12C. However, there are some axial positions that do not include the support structure 1027. In these examples, no bumper 10 is provided, and thus, a non-bumper collision cross beam 1029 arranged in the same manner as the bumper collision cross beam 1025 at other positions is provided, but since no bumper 10 is provided, no collision occurs during the operation of the system. The axial support bar 1022 provides axial structural support.

[0051] Therefore, at the input end, the tray support portion 1026 is connected via the bumper collision cross beam 1025. In this way, the connection rod interface bracket 1024 is arranged at the horizontal center and is connected to the bumper collision cross beam 1025 that extends the width of the tray 4 / 4' connected to the tray support portion 1026. As a result, the mechanical input from the rotary input mechanism 8 is transmitted to either side of the tray 4 / 4'. For the subsequent axial positions of the various trays 4 / 4', depending on the system requirements, the bumper 10 may or may not be included. If it is not included at a specific position, a non-bumper collision cross beam 1029 may be used instead of the bumper collision cross beam 1025.

[0052] The illustrated assembly includes two support structures 1027 (seen in the side views of FIGS. 11A and 11B) that extend axially along the assembly and are joined by the cross support portion 1031, and are also shown in the top view of FIG. 12A. The support structure 1027 provides axial structural support between the support bars 13 and also provides support for the fixed bumper mount 1020, while the cross beam support structure 1033 provides lateral cross beam support between the support structures 1027 as shown in FIG. 12C.

[0053] Therefore, during operation, based on the mechanical input from the drive arm 28, axial movement is input into the arrangement of the trays 4 / 4' by the bumper collision cross beam 1025 on the leftmost tray 4 via the connection rod interface bracket 1024. When the tray 4 / 4' is released at the top of the swinging motion, the tray 4 / 4' swings forward, and the bumper collision cross beam 1025 collides with the bumper 10 fixedly arranged on the fixed bumper mount 1020.

[0054] Accordingly, when the tray 4 / 4' contacts or collides with the bumper 10 and can no longer move further forward, the forward propelling force of the material to be conveyed 12 continues, overcoming the static friction of the material to be conveyed 12. Thereafter, the material 12 moves in the forward direction 40. The one-way continuous rotation mechanism 8 is configured such that when the tray 4 collides with the bumper 10, the input mechanism 8 then moves the tray 4 only in the reverse direction 32, reducing or eliminating excessive wear of the input mechanism 8. Thus, the input mechanism 8 does not deteriorate due to excessive wear and impact loads, thereby enabling the use of the system 2 without the maintenance and repairs required for other systems.

[0055] In one aspect, a conveyor system includes a tray suspended from above by two or more vertical supports and traveling in the forward direction from the uppermost point of the tray to the lowermost point of the tray. The system includes a one-way continuous rotation input mechanism that moves the tray in the reverse direction, opposite to the forward direction, to the uppermost point of the tray in the first stage of a single rotation cycle and allows the tray to freely fall in the forward direction without limitation in the second rotation cycle. The system includes a bumper arranged to suddenly stop the tray when the tray travels in the forward direction such that the tray rebounds and travels in the reverse direction while the material to be conveyed located on the tray continues to travel in the forward direction by the forward propelling force of the material to be conveyed.

[0056] In another aspect, a material conveying method includes moving the tray in the reverse direction in the first stage of a rotation cycle, releasing the tray to freely fall in the forward direction without limitation in the second stage of the rotation cycle, suddenly stopping the tray by a bumper when the tray travels in the forward direction, and rebounding the tray in the reverse direction such that the material to be conveyed on the tray continues to travel in the forward direction by the forward propelling force of the material to be conveyed, wherein the tray is configured to be moved by a one-way continuous rotation input mechanism.

[0057] When introducing elements of various embodiments of the disclosed material, the articles "a", "an", "the", and "said" are intended to mean that there is one or more elements. The terms "comprising", "including", and "having" are intended to be inclusive and mean that additional elements other than the recited elements may exist. Further, since the numerical examples in the following description are all non-limiting, additional numerical values, ranges, and percentages are within the scope of the disclosed embodiments.

[0058] It should be understood that the foregoing description has generally been provided in the context of a pendulum conveyor system, but the technology of the present invention is not limited to such a limited context. Providing examples and explanations in such a context is for ease of explanation by providing examples of implementation and application. The disclosed approach may be utilized in other contexts or configurations.

[0059] Although the disclosed material has been described in detail only in relation to a limited number of embodiments, it should be readily understood that the embodiments are not limited to such disclosed embodiments. Rather, the disclosed material can be modified to incorporate any number of variations, changes, substitutions, or equivalent arrangements not heretofore described, but which are within the spirit and scope of the disclosed material. Further, although various embodiments are described, it should be understood that the disclosed aspects may include only a portion of the described embodiments. Accordingly, the disclosed material is not limited by the foregoing description but only by the appended claims.

Claims

1. A tray suspended by two or more vertical support parts, the tray running in the positive direction from the uppermost point of the tray to the lowermost point of the tray or passing through the lowermost point of the tray, and the tray, A one-way continuous rotation input mechanism that moves the tray to the uppermost point in the reverse direction opposite to the positive direction in the first stage of a single rotation cycle, A one-way continuous rotation input mechanism that allows the tray to freely fall in the positive direction without limitation in the second stage of a single rotation cycle, A bumper arranged to suddenly stop the tray when the tray runs in the positive direction, whereby the tray bounces back and runs in the reverse direction, and the material to be conveyed located on the tray continues to run in the positive direction by the forward propulsion force of the material to be conveyed, including a positive direction bumper, a conveyor system.

2. The system according to claim 1, wherein the vertical support parts are arranged in a V shape with respect to each other.

3. The system according to claim 1, wherein two or more of the vertical support parts are straps.

4. The system according to claim 1, further including a fixed upper position where the vertical support part is suspended.

5. The system according to claim 1, wherein the one-way continuous rotation input mechanism includes a continuously rotating single-speed motor and a one-way bearing.

6. The system according to claim 5, wherein the one-way bearing is a sprag bearing.

7. The system according to claim 5, wherein the one-way bearing is a cam and a follower.

8. The system according to claim 5, wherein the one-way bearing is integrated with the continuously rotating single-speed motor.

9. Further including a first pulley wheel, a second pulley wheel and a belt, and the system according to claim 5, wherein the one-way bearing is coupled to the second pulley wheel via the first pulley wheel and the belt.

10. The system according to claim 9, further including a drive arm connected to the tray, and the one-way continuous rotation input mechanism is coupled to the tray by the drive arm.

11. The system according to claim 1, wherein the bumper is arranged beyond the lowermost point of the tray so that the tray is configured to run through the lowermost point of the tray.

12. The system according to claim 5, wherein a drive arm is coupled from the tray to the one-way continuous rotation input mechanism, and when the one-way continuous rotation input mechanism engages, the drive arm and the tray move relative to each other.

13. The system according to claim 1, wherein the tray includes side walls extending vertically from a base of the tray.

14. The system according to claim 1, further comprising a second tray supported by two or more of the vertical support portions.

15. The system according to claim 14, wherein the second tray is rigidly coupled to the first tray.

16. The system according to claim 14, wherein the second tray is loosely coupled to the first tray, the second tray is moved by the first tray, travels to the lowest point of the tray at a shorter distance than the first tray, and collides with the bumper before the first tray.

17. In a material conveying method, moving the tray in a reverse direction in a first stage of a rotation cycle and freely dropping and releasing the tray without restriction in a forward direction in a second stage of the rotation cycle so that the tray is configured to be moved by a one-way continuous rotation input mechanism; suddenly stopping the tray by a bumper when the tray travels in the forward direction; and rebounding the tray in a reverse direction so that the material to be conveyed on the tray continues to travel in the forward direction by a forward propulsion force of the material to be conveyed.

18. The method according to claim 17, further comprising suspending the tray from two or more vertical support portions.

19. The method according to claim 18, further comprising swinging the tray from two or more of the vertical support portions.

20. The method according to claim 17, further comprising coupling a drive arm from the tray to a one-way continuous rotation input mechanism.

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