Multidirectional conveyor roller

Abstract

Providing improved multi-directional conveyor rollers. [Solution] The conveyor roller is either externally driven, manually driven, gravity driven, or undriven, and secondary rolling elements are attached to the core of the conveyor roller to reduce friction of products moving across the effective surface of the roller in the opposite direction to the conveyor flow. The secondary rolling elements are arranged to rotate around multiple axes that are angled relative to the access of the conveyor roller. All rolling elements may be oriented at essentially the same angle. The secondary rolling elements can be incorporated into secondary rolling element assemblies that are easily fitted into openings defined in the core of the conveyor roller. Each assembly may be configured to snap into the openings in the core of the conveyor roller. In one embodiment, a pair of secondary rolling element assemblies may be configured to snap into the core from both sides, interconnected and supported.

Description

Technical Field

[0001] The present invention relates to a roller conveyor that uses a power-driven roller, a manually-driven roller, or a gravity-driven roller to convey a product downward in the longitudinal direction of the conveyor either forward or backward. In many material handling applications, the product must be moved laterally, or in a direction other than the main direction of the conveyor flow across the conveyor, while the conveyor system is either moving or stationary. The 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 the product to overcome lateral friction can pose an injury risk to the operator. Applying excessive lateral force to the roller can damage the roller bearings or the side frames of the conveyor. Existing solutions rely on a combination of multiple short conveyor rollers and multi-directional wheels mounted on a common shaft. This option is expensive due to the number of individual components involved. Also, this solution is not effective due to excessive shaft deflection resulting from multiple components being supported by a single shaft. Accordingly, the need for a conveyor roller that facilitates movement of the product in a direction other than the main direction of travel has remained unmet for many years.

Summary of the Invention

[0002] The present invention provides a conveyor roller having a secondary rolling element mounted within an effective conveying surface and extending above the outer conveying surface of the roller, which overcomes the disadvantages of the prior art by reducing the force required to move a product across the conveyor width, either while the conveyor system is moving or stationary.

[0003] In one embodiment, the conveyor roller has a shaft and a shell, and may have one or more bearings that rotatably support the shell on the shaft. Multiple secondary rolling elements are mounted within the outer surface of the outer shell and extend upward from that outer surface. The multiple secondary rolling elements are oriented to rotate about axes that are not parallel to the axis of the conveyor roller. In one embodiment, all secondary rolling elements rotate about multiple complementary axes in the sense that they facilitate the movement of products in a common direction different from the principal direction of movement related to the axis of rotation of the conveyor roller. For example, the secondary rolling elements may be positioned at approximately the same angle with respect to the axis of rotation of the conveyor roller. The number and arrangement of the rolling elements can be varied depending on the application.

[0004] In one embodiment, the present invention comprises a plurality of self-contained 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. If necessary, both ends of the shaft may be supported by bearings or bushings to facilitate the rotation of the shaft. The rolling elements are mounted on 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 on the shaft on bearings or bushings that potentially facilitate the rotation of the rolling elements around the shaft.

[0005] In one embodiment, each secondary rolling element assembly is mounted within the outer shell of the conveyor roller. The housing of each secondary rolling element assembly can be configured to be fitted into multiple openings in the shell.

[0006] In one embodiment, the housing is configured to snap into place within a plurality of corresponding openings in the shell. In one embodiment, the housing has a pair of projections configured to snap into and interconnect with the outer shell. The housing and / or projections can be manufactured from a material that is sufficiently flexible and elastic to allow the projections to flex inward as they snap into the openings, but also to spring outward to interconnect.

[0007] In one embodiment, a plurality of secondary rolling elements are arranged around the conveyor roller in a pattern selected to maintain the structural integrity of the outer shell. For example, these secondary rolling elements may be arranged in multiple rows extending around the conveyor roller, and each row may be longitudinally offset from an adjacent row such that the secondary rolling elements of one row do not overlap with the secondary rolling elements of one or more adjacent rows along the periphery path.

[0008] The present invention provides an effective and durable conveyor roller assembly that facilitates the movement of conveyed products in directions other than those related to the rotation axis of the conveyor roller. The invention addresses the shortcomings of both cost and strength of existing solutions by incorporating secondary rolling elements within the roller's tubular core. 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 use of snap-fit ​​secondary rolling element assemblies facilitates assembly, repair, and replacement. Furthermore, different types of secondary rolling elements can be interchangeably mounted on a given conveyor roller, for example, to accommodate different products or changes in the conveyor path.

[0009] These and other purposes, advantages, and features of the present invention will be more fully understood and recognized by referring to the description and drawings of this embodiment.

[0010] Before describing embodiments of the present invention in detail, it should be understood that the present invention is not limited to the operational details, configuration details, and arrangement of components described in the following description or shown in the drawings. The present invention can be carried out in various other embodiments and in alternative ways not expressly disclosed herein. It should also be understood that the expressions and terms used herein are for illustrative purposes only and should not be taken as limiting. The use of the words “including” and “comprising” and their variations means that the following enumerated items and their equivalents, as well as additional items and their equivalents, are included. Furthermore, enumerations may be used in the description of various embodiments. Unless otherwise specified, the use of enumerations should not be construed as limiting the present invention to any particular order or number of components. Nor should the use of enumerations be construed as excluding from the scope of the present invention any additional steps or components that can be combined with or incorporated into the enumerated steps or components. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a top view of a multi-directional roller according to one embodiment of the present invention. [Figure 2] Figure 2 is a front view of the multi-directional roller. [Figure 3] Figure 3 is a cutaway view of a multidirectional roller having a rolling element assembly according to the first embodiment. [Figure 4] Figure 4 is a cutaway view of the rolling element assembly according to the first embodiment. [Figure 5] Figure 5 is a cutaway view of an alternative multi-directional roller having a rolling element assembly according to the second embodiment. [Figure 6] Figure 6 is a cutaway view of an alternative rolling element assembly according to the second embodiment. [Figure 7] Figure 7 is a top view of another alternative multidirectional roller having a rolling element assembly according to the third embodiment. [Figure 8]Figure 8 is a top view of the conveyor with conveyor rollers from Figure 7, showing its operation when configured as a diverter. [Modes for carrying out the invention]

[0012] Figure 1 shows a first embodiment of the present invention, which features a conveyor roller 20 having a plurality of rolling elements 2 mounted on a roller core 1 in a pattern arranged around the roller 4 and along the length of the effective width. The conveyor roller 20 is configured to rotate about a main axis 5 so that the supported product can move in a direction perpendicular to the main axis 5. In the illustrated embodiment, each rolling element 2 is oriented such that its axis of rotation 6 is perpendicular to the main axis (or the axis of rotation 5 of the conveyor roller core 1). As shown in Figure 2, these rolling elements 2 are arranged to seat on or above the outer surface of the conveyor roller 20 so as to engage with the product supported on the conveyor roller 20. The number, dimensions, shape, and arrangement of the rolling elements can be varied depending on the application.

[0013] The present invention describes and illustrates one type of conventional conveyor roller 20, but it can be incorporated into a wide range of alternative conveyor rollers of different dimensions, shapes, and configurations. For example, in one application, the conveyor roller may be a dead shaft roller with an integrated bearing that provides rotation of the outer shell relative to the inner shaft. In other applications, the conveyor roller may have a live shaft, in which the inner shaft and outer shell are fixed together, and the conveyor roller rotates through the use of an external bearing assembly that supports both ends of the shaft. Since such techniques are generally well known, other features and components of the conveyor roller 20 will not be described in detail.

[0014] In the illustrated embodiment, the conveyor roller 20 is a dead-shaft roller, and the core 1 has a shaft 22, a tubular outer shell 24, and a pair of bearing assemblies 26. The shaft 22 is configured to be fixed (non-rotatable) mounted to a frame F that supports the roller conveyor assembly RCA (see, for example, Figure 8). The outer shell 24 is arranged concentrically around the shaft 22 and is rotatably connected to the shaft 22 by the bearing assemblies 26. In this embodiment, the bearing assemblies 26 are conventionally operably fitted between the shaft 22 and the outer shell 24 at or near both ends of the outer shell 24 to facilitate the rotation of the outer shell 24 around the shaft 22. To accommodate the installation of rolling element assemblies 28 (described in more detail below), the outer shell 24 defines a number of openings 40, each sized and shaped to tightly receive the rolling element assemblies 28. More specifically, each opening 40 corresponds to the cross-sectional shape of the housing 3. For alternative applications, the structure of the conveyor roller 20 can be modified to accommodate different rolling elements and / or different rolling element assemblies.

[0015] In the illustrated embodiment, the rolling element 2 generally comprises a shaft 32 and a roller 34. In the illustrated embodiment, the shaft 32 is a dead shaft in the sense that it is fixed and does not rotate with the roller 34. In an alternative embodiment, the shaft 32 may be a rib shaft configured to rotate with the roller 34. The shaft 32 and the roller 34 may be manufactured separately from the desired material, and the two components may be assembled to form the rolling element 2. In this type of application, the shaft 32 may be metal, and the roller 34 may be injection molded from plastic. If necessary, the roller may be made from a highly lubricating plastic such as PTFE or ultra-high molecular weight polyethylene (UHMW-PE) to facilitate the rotation of the roller 34 around the shaft 32, although other plastics may be more suitable depending on the application. In some embodiments, the shaft 32 and the roller 34 may be a single, one-piece structure. For example, the shaft 32 and roller 34 can be molded simultaneously from a common material in a single injection molding step, or they can be molded from different materials in succession, such as by injection molding the shaft from a first material and then injection molding the roller onto the shaft at a predetermined position from a second material. As another example, the shaft may be manufactured in advance and the rollers may be injection molded at a predetermined position around the shaft. These are merely examples, and the rolling element 2 can be manufactured using essentially any suitable manufacturing technique and equipment. In applications with a ribbed shaft rolling element, both ends of the shaft 32 can be supported by bearings, bushings, or other low-friction elements to facilitate the rotation of the shaft 32.

[0016] As shown in Figure 2, the roller 34 is configured to partially protrude above the outer shell 24 and provide a contact surface that is generally parallel to the exposed surface around the outer shell 24. This is merely illustrative, and the dimensions, shape, and configuration of the roller 34 can also be varied depending on the application. For example, the height of the roller 34 above the outer shell 24 and / or the length of the roller 34 can be changed. Another example is that the exposed surface of the roller 34 can have a different shape that is not parallel to the outer shell 34.

[0017] 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-supporting unit that can be mounted on the conveyor roller 20. In the illustrated embodiment, all rolling element assemblies 28 are essentially the same, each fitting to the conveyor roller 20 in essentially the same way, meaning they can be interchangeably mounted anywhere along the conveyor roller 20. In alternative applications, the rolling element assemblies 28 and mounting structures can vary depending on the location. While using self-contained rolling element assemblies offers advantages in some applications, the rolling elements 2 can also be integrated into the conveyor roller 20 using alternative configurations. For example, each rolling element 2 may be mounted directly to the conveyor roller 20 and may not be integrated into the rolling element assembly 28.

[0018] In the illustrated embodiment, each rolling element assembly 28 has a housing 3 and a rolling element 2 (the illustrated rolling element 2 has a shaft 32 and a roller 34). The illustrated housing 3 is generally rectangular and forms a well deep enough to accommodate most of the rolling element 2. The illustrated housing 3 also has a tapered flange 7 that surrounds the opening of the housing 3 and is configured to seat on the surface of the outer shell 24 when installed. For example, the illustrated housing 3 has a continuous flange 7 that extends around the periphery of the housing 3 and is recessed into and flush with the exposed surface of the outer shell 24 when installed on the conveyor roller 20. The flange 7 is tapered to prevent it from being pushed into the interior of the outer shell 24 through the opening 40. In the illustrated embodiment, the opening 40 is configured to have a matching taper that allows the flange 7 to be fitted flush into the opening 40. The illustrated taper is for illustrative purposes only, and the angles of the flange and opening tapers can vary depending on the application. Furthermore, it should be understood that the illustrated flange is merely illustrative, and the dimensions, shape, and configuration of the flange can vary depending on the application. For example, the flange can be discontinuous, or relatively large or small. In other applications, the flange 7 can be fitted differently from the outer shell 24. For example, in some applications, the flange can completely or partially overlap the surface of the outer shell 24. As another example, the periphery of each opening 40 of the outer shell 24 can be dish-shaped to receive all or part of the flange 7.

[0019] In the illustrated embodiment, each rolling element assembly 28 is configured to snap into a predetermined position within the opening 40 of the conveyor roller 20, but in an alternative embodiment, the rolling element assembly can also be fixed to the conveyor roller. To provide a snap-fit ​​configuration, the illustrated housing 3 has a pair of outwardly extending locking protrusions 9 designed to fit with the outer shell 24 of the conveyor roller 20. As shown, for example in Figures 3 and 4, the locking protrusions 9 extend outward from the housing 3. The locking protrusions 9 in the illustrated embodiment are shaped to facilitate insertion into the opening 40 while resisting removal. For example, the locking protrusions may have a somewhat pyramidal shape with tapered surfaces as shown. The degree of taper can be varied from surface to surface and from application to application. For example, the inward-facing surface may be relatively long and have a gentler taper (to facilitate insertion into the opening), while the outward-facing surface may have a steeper angle to help hold the rolling element assembly 28 within the outer shell 24. In the illustrated embodiment, the housing 3 is manufactured from a suitable resin or polymer material using generally conventional injection molding techniques and equipment. In alternative embodiments, the housing may be manufactured from essentially any alternative material suitable for the application using corresponding manufacturing techniques and equipment.

[0020] Depending on the application, the rolling element assembly 28 may be sized to abut against a shaft 22 extending through the center of the conveyor roller 20, or against some other structure inside the conveyor roller 20. This can help provide structural support to the rolling element assembly 28 by resisting inward movement of the assembly 28 against the outer shell 24. This option may be more practical with respect to rib-shaft conveyor rollers 20 and / or dead-shaft conveyor rollers, where the shaft has a circular cross-section.

[0021] In the embodiment shown in Figure 3, each rolling element assembly 28 is installed within the outer shell 24 by pushing it into the opening 40 of the roller core 1 until it snaps into place. Featured parts on the housing 3 (e.g., locking projections 9) are designed to flex inward, allowing them to fit through the opening 40 of the roller core and then return to their predetermined positions within the roller core 1. These features prevent the assembly from falling off the roller as it rotates. Flange elements 7 on the upper portion of the housing prevent the assembly from falling further into the opening 40 and provide means for supporting the load of the cargo. In this embodiment, as shown in Figure 4, each rolling element 2 rotates around a fixed shaft 32 fitted within the housing 3. Each housing 3 contains a single rolling element 2, which can be varied in alternative applications. The illustrated rolling element assembly 28 is for illustrative purposes only. The design and configuration of the illustrated rolling element 2 and rolling element assembly 28 can be varied for each application (and potentially for each location on the same conveyor roller). Furthermore, the method of fixing the rolling element assembly 28 within the conveyor roller 20 can be varied depending on the application. For example, the rolling element assembly 28 can be fixed using alternative structures such as alternative snap-fit ​​components (e.g., spring plungers), fasteners, chemical mounting, welding, and / or adhesives.

[0022] The second embodiment of the present invention shown in FIGS. 5 and 6 features a rolling element assembly 28' with an additional extension 10' at the bottom of the housing 3', such that two identical housings 30' can be snap - engaged together within the roller core 1'. In this embodiment, the two identical housings 30' are fitted into the outer shell 24' from both sides and are fitted around the shaft 22'. The housing extension 10' features tabs 11' or slots 12' that engage with tabs 11' or slots 12' from the identical housing 3' on both sides of the roller core. The tabs 11' and grooves 12' can be configured to interconnect in some applications to help hold the connection between the two housing extensions 10' of adjacent rolling element assemblies 28'. For example, the tab 11' of one housing extension 10' can be friction - fitted into the slot 12' of another housing extension 10', or the tabs 11' and slots 12' have snap - fit features (such as recesses and engaging protrusions) that allow them to interconnect so that they resist separation. This embodiment can add further strength and can be particularly useful when heavy products are being transported and / or when impact loads can occur. When engaged together, the product load on one assembly 28' can be transmitted to the second assembly 28', and both components can share the load when supporting the product load. The illustrated housing extension 10' is merely exemplary and can be varied for each application. For example, the dimensions, shape, and configuration of the extension 10' can be changed. In alternative applications, the connection mechanism can also be changed. The number of interconnected rolling elements can be varied for each application. For example, the housing extension can be configured to allow three or four rolling element assemblies symmetrically arranged around the conveyor roller 20' to be interconnected.

[0023] A third embodiment of the present invention is shown in Figures 7 and 8, characterized by a rolling element 2" whose rotation axis 13" is oriented at an oblique angle with respect to the rotation axis 14" of the conveyor roller 20". This embodiment is particularly useful in driven roller conveyors that have several methods for stopping the forward movement of a product, as shown in Figure 8, but may also be useful in other applications. When no other forces are acting on the product P1 being conveyed, the product P2 descends on the conveyor in the flow direction D1 with little movement of the rolling element 2". When the stopping unit 23" prevents the product P2 from descending on the conveyor, the support roller 24" below the product P2 continues to rotate, and as a result, the rolling element 2" rotates relative to the bottom surface of the product P2. Due to the rotation angle of the rolling element 2", the first part of the rotation counteracts the rotation of the conveyor roller 20", reducing back pressure on the product. The second part of the rotation applies a lateral force to the product P2, causing the product P2 to move laterally along the surface of the stopper 23" in the direction of arrow D2. The angle shown in the figure is for illustrative purposes only, and the rolling element 2" can be oriented at essentially any angle with respect to the axis of rotation of the conveyor roller 24". In some applications, the angle of the rolling element 2" can be varied along the length of the conveyor roller 24". For example, the rolling elements 2" on one opposing half of the conveyor roller 24" can be oriented in different directions to move products left and right depending on their position on the conveyor roller 24".

[0024] The preferred embodiment described is a snap-fit, but other embodiments may be chemically bonded or engaged to the core in some other way. The preferred embodiment described is made from injection-molded plastic, but others may be made from other materials or by other manufacturing methods depending on the needs of the particular application. The preferred embodiment described has a single-piece rolling element made from a homogeneous material, but others may be made in a two-piece design having a harder inner part to facilitate easy rotation and an outer part made of a different material to provide application-specific benefits when in contact with the product. The preferred embodiment uses a separate metal shaft for the axis of the rolling element, but others may have a plastic shaft incorporated into the housing design. The preferred embodiment is designed around an industrial standard diameter 4.8 cm (1.9 inch) conveyor roller, but can be easily scaled to smaller or larger diameter roller applications. The preferred embodiment shown in Figure 1 features rolling elements arranged in a pattern that strikes a balance between the strength and functionality of the tube. This pattern is intended to be modified depending on the needs of the particular application.

Claims

1. In conveyor rollers, The aforementioned conveyor roller is A roller core having a conveying surface that can rotate around its main axis, A conveyor roller comprising a plurality of rolling elements installed inside the roller core, each of which rolling elements is rotatable about an axis different from the main axis of the roller core.

2. The conveyor roller according to claim 1, wherein the plurality of rolling elements are regularly arranged around the conveyor roller and along its length.

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

4. The conveyor roller according to claim 3, wherein the plurality of rolling elements are mounted in a housing that engages with the roller core.

5. The conveyor roller according to claim 4, wherein each of the plurality of rolling elements is rotatable about an axis perpendicular to the main axis.

6. The conveyor roller according to claim 4, wherein each of the plurality of rolling elements is rotatable about an axis oblique to the main axis.

7. The conveyor roller according to claim 2, wherein the plurality of rolling elements are arranged along the perimeter and length of the conveyor, and two or fewer rolling elements are arranged along a single perimeter.

8. The conveyor roller according to claim 2, wherein the plurality of rolling elements are arranged in multiple pairs along the perimeter and length of the conveyor, and one or fewer pairs of rolling elements are arranged along a single perimeter.

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

10. In a conveyor roller assembly, The aforementioned conveyor roller assembly is Multiple conveyor rollers arranged in a row, The first conveyor roller among the plurality of conveyor rollers, A first outer shell forming a first primary rolling element, the first outer shell being rotatable about a first principal axis, A first conveyor roller among a plurality of conveyor rollers, having a plurality of first secondary rolling elements installed within the first outer shell, each of which is rotatable about an axis different from the first main axis, The second conveyor roller among multiple conveyor rollers, A second outer shell forming a second primary rolling element, the second outer shell being rotatable about a second principal axis, A plurality of second secondary rolling elements installed within the second outer shell, each of which is rotatable about an axis different from the second main axis, and a second conveyor roller among a plurality of conveyor rollers, the plurality of second secondary rolling elements having a plurality of second secondary rolling elements, A conveyor roller assembly comprising a plurality of conveyor rollers, wherein the first conveyor roller among the plurality of conveyor rollers is positioned adjacent to the second conveyor roller among the plurality of conveyor rollers, thereby the first conveyor roller and the second conveyor roller among the plurality of conveyor rollers cooperate to define a product conveying surface.

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

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

13. The conveyor roller assembly according to claim 10, wherein each of the plurality of first secondary rolling elements is rotatably arranged within a housing, and each housing is fitted into a corresponding opening in the outer shell of the first conveyor roller among the plurality of conveyor rollers.

14. The conveyor roller assembly according to claim 13, wherein each housing is snap-fitted into a corresponding opening in the outer shell of the first conveyor roller of the plurality of conveyor rollers.

15. The conveyor roller assembly according to claim 14, wherein each housing has a flange that operably 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 has a shaft and a roller, the roller is arranged around the shaft and the shaft is snap-fitted into a housing.

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

18. The conveyor roller assembly according to claim 17, wherein each of the plurality of housings has at least one extension, and each housing has at least one housing extension, and the rolling element assemblies are mounted in pairs such that one housing extension of the plurality of rolling element assemblies engages with the other housing extension of the plurality of rolling element assemblies.

19. In conveyor rollers, The aforementioned conveyor roller is A shaft extending along the main axis, An outer shell positioned concentrically with respect to the shaft, the outer shell having an outer circumferential surface for supporting the product carried by the conveyor roller, and being rotatable about the main axis, the outer shell defining a plurality of openings, A conveyor roller comprising a plurality of secondary rolling elements mounted within the outer shell, wherein the plurality of secondary rolling elements are regularly arranged around the outer shell and along its length, and each of the secondary rolling elements has a shaft and a roller, the roller protruding above the outer circumferential surface of the outer shell and oriented to rotate about an axis different from the main axis.

20. Each of the plurality of secondary rolling elements is rotatably mounted to a housing, and each housing is fixed inside a corresponding opening among the plurality of openings of the outer shell, the conveyor roller according to claim 19.

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