Snap-Lock Conveyor Components

Abstract

A conveyor component for use in a conveyor includes a flexible borehole for mounting the conveyor component to a shaft, the flexible borehole including a clearance region for sliding the component on an associated shaft in a first orientation and a retention feature for locking the component on the mounting region of the shaft in a second orientation.

Description

[Technical Field]

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 63 / 440,523, entitled "Snap Lock Conveyor Component," filed January 23, 2023, the contents of which are incorporated herein by reference.

[0002] This application relates to power driven conveyors. More particularly, the present invention relates to rollers and other components used to support a conveyor belt in the return path, infeed, or anywhere else the conveyor belt requires support. [Background technology]

[0003] Conveyor belts are used in many industries to transport products from a first location to a second location. Conveyor belts typically form an endless belt loop around drive and idler sprockets or rollers at each end of the conveying path. Articles transported on the conveyor belt are supported along a lower carryway. The conveyor belt returns along a lower returnway. Return shoes or rollers are often used to optimize maximum conveyor belt slack on the returnway. Return rollers typically span the width of the conveyor belt at selected locations along the returnway and are mounted on a shaft. Rollers may also be used to support the conveyor belt at the infeed end and / or elsewhere in the endless conveyor belt circuit. Other shaft-mounted components are also used to support, house, and / or guide the conveyor belt.

[0004] Mounting such conveyor components on a shaft often involves the use of separate retention mechanisms that increase the complexity of the system and can cause hygiene and / or breakage issues. Summary of the Invention

[0005] A conveyor component for mounting to a shaft having a contoured corner at a mounting region includes a flexible borehole having a clearance region corresponding to the corner of the shaft for sliding the component on the associated shaft in a first orientation and a retention feature for locking the component onto the mounting region of the shaft in a second orientation.

[0006] According to one aspect, a combination of a shaft for a conveyor system and a roller mounted thereon includes a shaft extending along a longitudinal axis and having n flat surfaces intersecting at n corners and a plurality of mounting regions, each mounting region including a beveled surface at each corner of the shaft. The roller includes a body having a flexible borehole defined by n shaped sections. Each shaped section includes a first portion forming a clearance area for a corresponding corner, the first portion transitioning to a first flexible tab for receiving the shaft by contacting a first edge of the beveled surface, the first flexible tab transitioning to a retaining recess, and the retaining recess transitioning to a second flexible tab for contacting a second edge of the beveled surface.

[0007] According to another aspect, a conveyor component includes a body and a flexible borehole for attaching the body to a shaft, the flexible borehole being defined by n shaped sections, each shaped section including a first gap portion, the first gap portion transitioning to a first flexible tab, the first flexible tab transitioning to a retaining recess, the retaining recess transitioning to a second flexible tab, and a second gap portion, identical to the first gap portion, extending from the second flexible tab and terminating at the beginning of a successive shaped section.

[0008] According to another aspect, a method of mounting a roller to a shaft in a conveyor system includes aligning a corner of the shaft with a clearance area of ​​the roller in a borehole, sliding the roller along the shaft until the mounting area of ​​the shaft is within the borehole, and rotating the roller about the shaft so that a beveled surface of the mounting area of ​​the shaft snaps into a retention feature in the borehole. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is an isometric view of a roller assembly for a conveyor, according to one embodiment. [Figure 2] FIG. 2 is an isometric view of the shaft of the roller assembly of FIG. [Figure 3] FIG. 3 is a front view of the shaft of FIG. [Figure 4] 4 is a front view of a roller of the roller assembly of FIG. 1. FIG. [Figure 5] FIG. 5 is a detailed view of the borehole of the roller of FIG. [Figure 6] FIG. 6 is a detailed view of the forming section of the borehole of FIG. [Figure 7] FIG. 7 is another view of the forming section of FIG. [Figure 8A] FIG. 8A shows a sequence of steps for attaching a roller to a shaft, according to one embodiment. [Figure 8B] FIG. 8B illustrates a sequence of steps for attaching a roller to a shaft, according to one embodiment. [Figure 8C] FIG. 8C illustrates a sequence of steps for attaching a roller to a shaft, according to one embodiment. [Figure 9A] FIG. 9A is a cross-sectional view of the roller and shaft of FIGS. 8A-8C during the process of attaching the roller to the shaft. [Figure 9B] FIG. 9B is a cross-sectional view of the roller and shaft of FIGS. 8A-8C during the process of attaching the roller to the shaft. [Figure 9C] FIG. 9C is a cross-sectional view of the roller and shaft of FIGS. 8A-8C during the process of attaching the roller to the shaft. [Figure 10] FIG. 10 is a side view of a roller and shaft of a roller assembly including an angled receiving surface in the mounting area of ​​the shaft, according to another embodiment. [Figure 11A] FIG. 11A shows a portion of a roller assembly and a tool for locking a roller onto the shaft of the roller assembly according to another embodiment. [Figure 11B] FIG. 11B shows a portion of a roller assembly and a tool for locking a roller onto the shaft of the roller assembly according to another embodiment. [Figure 11C] FIG. 11C shows a portion of a roller assembly and a tool for locking the roller to the shaft of the roller assembly according to another embodiment. [Figure 12] FIG. 12 shows a portion of a roller assembly including an opening in the body of the roller and a tool for locking the roller to a shaft according to another embodiment. [Figure 13] FIG. 13 shows a portion of a roller assembly and a tool for locking a roller onto the shaft of the roller assembly according to another embodiment. [Figure 14] FIG. 14 is a front view of a roller illustrating the geometry used to determine a preferred borehole, according to one embodiment of the present invention. [Figure 15] FIG. 15 shows the geometry of FIG. [Figure 16] FIG. 16 is a detailed view of a portion of the geometry of FIG. [Figure 17] FIG. 17 shows a flexible borehole configuration according to another embodiment. [Figure 18] FIG. 18 shows a flexible borehole configuration according to another embodiment. [Figure 19] FIG. 19 shows a flexible borehole configuration according to another embodiment. [Figure 20] FIG. 20 shows a flexible borehole configuration according to another embodiment. [Figure 21] FIG. 21 shows a flexible borehole configuration according to another embodiment. [Figure 22] FIG. 22 shows a flexible borehole configuration according to another embodiment. [Figure 23] FIG. 23 shows a flexible borehole with an open space according to another embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] Conveyor components, such as rollers, include flexible hubs for attaching the rollers to the shaft and locking the components onto the shaft. Although the present invention is described below with reference to certain exemplary embodiments, those skilled in the art will recognize that the invention is not limited to the described embodiments.

[0011] 1-2, a conveyor assembly, shown as conveyor roller assembly 10, includes a series of conveyor rollers 100 mounted on mounting shaft 12 within the conveyor. The exemplary series of conveyor rollers 100 are evenly spaced at mounting areas 14 along the axial length of the mounting shaft, although the invention is not so limited and any number of conveyor rollers 100 may be mounted in any suitable location and / or pattern. In one embodiment, the conveyor rollers are returnway rollers mounted in the returnway of a conveyor to guide and / or support a conveyor belt as it travels from the outfeed discharge end back to the infeed of the conveyor. The conveyor belt may rotate the conveyor roller assembly 100 as it travels over the outer rims 160 of the conveyor rollers 100. During operation, the exemplary rollers 100 are fixedly mounted on mounting shaft 12, with end journals 15 inserted in bearings to allow the entire assembly 100 to rotate in unison. Those skilled in the art will recognize that the exemplary conveyor roller assembly may be implemented in any suitable location within a conveyor, such as an in-feed or other suitable location where support for a conveyor belt is useful. Other suitable types of conveyor components may be similarly mounted to the shaft.

[0012] As shown in FIGS. 2 and 3 , the exemplary mounting shaft 12 has a substantially square cross-section defined by four corners 16 and four flat sidewalls 18. In each mounting region 14, the corners 16 are cut or otherwise shaped to form beveled surfaces 17 that reduce the overall size of the shaft 12 in that region. The exemplary beveled surfaces 17 are convexly curved and extend from a first edge 171 to a second edge 172. The exemplary beveled surfaces 17 form an arc of a circle 175 having a diameter D that is greater than the height H (and therefore width) of the square shaft 12 but less than the diagonal G of the square shaft 12. The circle 175 is centered on the shaft 12. As shown, the imaginary arc of the circle 175, which does not include the beveled surfaces 17, extends outside the flat sidewalls 18 of the shaft 12.

[0013] The beveled surfaces 17 form a substantially triangular containment wall 19 to aid in axially containing the roller 100. The exemplary containment wall 19 extends perpendicular to the longitudinal axis of the shaft, although the containment wall may alternatively be angled or otherwise configured.

[0014] The rollers 100 may include flexible hubs to simplify installation and removal of each roller from the mounting shaft 12. Each roller can be snap-locked to the shaft 12 at its corresponding mounting region 14 by rotating the roller 100 a selected angle, as described below. As shown in FIG. 4 , each roller 100 has a substantially disk-shaped molded body with a radially outer rim 160 extending axially from a first side 124 to an opposite second side across the axial width or thickness of the roller. A borehole 122 for receiving the mounting shaft 12 extends along a longitudinal axis 125 from the first side 124 to the second side and is defined by an inner edge 128. The roller can have a solid body or a body with spokes connecting the inner edge 128 of the borehole 122 to the outer rim 160 or other suitable connector.

[0015] As shown in FIG. 5 , the inner edge 128 is formed by a series of formed sections 130 a, 130 b, 130 c, and 130 d joined end-to-end to define the central bore 122. The inner edge 128 forms a shape that is rotationally symmetric about the longitudinal axis 125 by a factor of n, where n is the number of corners 16 on the associated mounting shaft 12, which is four in the exemplary embodiment. The formed sections 130 a, 130 b, 130 c, and 130 c cooperate to form four clearance areas 129 for the corners 14 of the shaft 12. Each clearance area is formed at the intersection of two consecutive formed sections 130. The inner edge 128 also forms retention features for retaining the shaft 12 between the clearance areas 129 when the shaft is in a selected orientation within the borehole 122.

[0016] Referring to FIG. 6 , each formed section 130 of the inner edge 128 includes a retention area between the end gap regions. In an exemplary embodiment, the formed section 130 begins at a first point 132. A first concave curve 131 traces an approximately 90-degree arc from the first point 132 to a second point 133, forming half of the gap region 129 together with the concave curves of adjacent formed sections. At point 133, the formed section 130 bends into a convex curve 134 to form a first flexible retention tab that protrudes inward into the roller bore hole 122. The convex curve 134 has a radius of curvature that is smaller than the radius of curvature of the first concave curve 131. At a bending point 135, the formed section 130 transitions into a shallow concave curve 136 to form a retention recess. The shallow concave curve 136 has a radius of curvature that is larger than the radius of curvature of the first concave curve 131. The shallow concave curve 136 extends across a small central angle, which may be about 30 degrees to about 60 degrees, preferably about 45 degrees, and then bends at another bend point 137 into another convex curve 138 to form a second flexible retention tab. The second convex curve 138 is substantially identical to the first convex curve 134. The second convex curve 138 bends at a bend point 139 into a third concave curve 140 that is identical to the first concave curve 131, forming one half of the second gap area for the second corner 14 of the shaft. The end 141 of the third concave curve 140 coincides with the start 132 of the continuous formed section 130.

[0017] The exemplary forming section 130 has mirror symmetry about a midpoint that coincides with the nadir 143 of the shallow retention curve 136 .

[0018] 7, bending points 133, 135, 137, and 139 and end points 132, 141 of formed section 130 are aligned along line L. End concave curves 131, 140 have an amplitude A1 (the distance from line L to the top of the curve) that is greater than the amplitude A2 of curves 134, 138. While amplitude A2 of curves 134, 138 is greater than amplitude A3 of retaining recess 136 in the illustrated embodiment, the invention is not so limited; alternatively, amplitude A3 of retaining recess 136 may be greater.

[0019] Chord C1 between points 132 and 133 has a length slightly greater than the length of chord C3 between points 135 and 137. Chord C2 extending between points 133 and 135 is smaller than chords C1 and C3. In one embodiment, chord C3 has a distance approximately equal to the distance between edges 171, 172 of shaft bevel 17 at attachment region 14.

[0020] The present invention is not limited to the exemplary formed section 130, and the inner edge 128 may have any suitable configuration that forms a gap area and a retention section, as described below.

[0021] 8A-8C illustrate the sequence for mounting a roller 100 to a square shaft 12, according to one embodiment. First, as shown in FIG. 8A, the four corners 16 of the square shaft 12 are axially aligned with the clearance area 129 formed by the large concave curve 131. In this position, the roller 100 is free to move along the length of the shaft 12. The roller 100 is then slid axially along the shaft 12 to the desired axial position, so that the mounting area 14 is within the borehole 122, as shown in FIG. 8B. The roller 100 is then rotated 45 degrees in either direction to snap the roller 100 into a locked position on the shaft 12, as shown in FIG. 8C. The roller 100 is then locked onto the shaft 12 by placing the beveled surfaces 17 in the mounting area 14 into the retention area formed in the borehole 122, thereby locking the roller 100 onto the shaft 12. The flexible borehole 122 flexes slightly to accommodate rotation of the shaft 12 before locking onto the shaft in a locked position.

[0022] In the locked position, the triangular containment walls 19 of the mounting area abut the sides 124 of the roller 100 near the retention area of ​​the borehole inner edge 128 to help contain the roller axially along the shaft.

[0023] 9A-9C are cross-sectional views of a portion of shaft 12 and the borehole of roller 100 during attachment of roller 100 to shaft 12. As shown in FIG. 9A, when corner 16 is aligned with gap region 129 formed by cooperating formed sections 130a, 130b, corner 16 and sidewall 18 are spaced apart from formed sections 130 that define inner edge 128 of borehole 122. Each beveled surface 17 of the shaft attachment region extends from a first edge 171 of first wall 18 to a second edge 172 of second sidewall 18.

[0024] Referring to FIG. 9B, as the roller 100 rotates relative to the shaft 12, the first edge 171 of each formed corner 17 contacts the first flexible retention tab formed by the first convex curve 134. As torque is applied, the flexible retention tab 134 bends away from the first edge 171 and slides the ramp 17 into the retention recess formed by the shallow concave curve 136, as shown in FIG. 9C. In the locked position shown in FIG. 9C, the flexible retention tabs 134, 138 straddle the ramp 17 to accommodate the shaft 12. The first edge 171 of the ramp 17 abuts the inflection point 137 between the shallow concave curve 136 and the second flexible tab 138, and the second edge 172 of the ramp abuts the inflection point 135 between the shallow concave curve and the first flexible tab 134, retaining the shaft 12.

[0025] Roller 100 can be unlocked and removed from shaft 12 by rotating the roller 45 degrees in either direction so that corner 16 is aligned with gap area 129, disengaging attachment area 14 from flexible retention tabs 134, 138. Roller 100 can then be slid axially along shaft 12.

[0026] In one embodiment shown in FIG. 10, the shaft 12' can have a sloped receiving wall 19' that forms the axial end of the attachment region 14'.

[0027] While a roller 100 or multiple rollers 100 can be manually attached to an associated shaft 12, in one embodiment, the rollers can be configured to engage an installation tool to simplify assembly and / or disassembly of the roller assembly. For example, in one embodiment shown in FIGS. 11A-11C, an installation tool 200 can be used to rotate the shaft 12 relative to the roller 100. The installation tool includes a handle 210 that terminates in a C-shaped cradle 220 for holding the shaft 12. Fingers 221 extend from the tip of the cradle 220 and are configured to be inserted into the gap region 129 between the shaft 12 and the roller 100, as shown in FIG. 11B. As the installation tool 200 is rotated, it snaps the shaft 12 into a locked position within the borehole 122.

[0028] 12 and 13, a roller 300 with flexible boreholes may include holes 310 or other features that engage a tool, shown as a screwdriver 320 or Allen wrench 330, to facilitate rotation of the roller 300 about the shaft 12 and selectively lock the roller 300 onto the shaft. Other suitable tools may also be used.

[0029] The present invention is not limited to exemplary boreholes for mounting rollers to a mounting shaft and locking them without the use of tools. For example, Figures 14-16 illustrate boundaries used to design the parameters of a flexible borehole for a roller 400 or other conveyor component, according to one embodiment. The flexible borehole can be defined by a first shape shown as a square 416 corresponding to the shaft wall 16 where the roller 400 will be mounted. The flexible borehole can be defined by a circle 475 centered on the square 416 and defining the beveled surface 17 of the shaft corner cut that forms the mounting area. Diamond 418 corresponds to square 416 rotated 45 degrees.

[0030] A first portion of the shaped section, forming one half of the gap area, extends outside the boundaries defined by square 416, diamond 418, and circle 475 and can be formed anywhere within region 481 terminating at point 433 (the intersection of circle 475 and diamond 418). A first flexible protrusion of the shaped section can be formed in region 434 outside diamond 418 and square 416 but inside circle 475. Point 435 (the intersection of circle 475 and square 416) defines a transition between the first flexible protrusion and the retaining recess for accommodating beveled surface 17 of mounting shaft 12. The retaining recess can have any size, shape, and configuration outside circle 475 in region 482 between points 435 and 437 (the second intersection of circle 475 and square 416). A second flexible protrusion is formed in region 438, a second region formed between points 437 and 439 inside circle 475 but outside both square 416 and diamond 418. A final portion of the molded section, which forms part of the second gap region for the corner, extends from point 439 in region 483 outside square 416, diamond 418, and circle 475.

[0031] 17-22 show examples of boreholes for conveyor components such as rollers that include multiple shaped sections that create gap and retention areas designed using the parameters described with respect to FIGS. 14-16.

[0032] 17 shows a borehole 522 including shaped sections 530a, 530b, 530c, and 530d. Each shaped section includes a first gap section 531 extending outside the shaft wall, a first flexible protrusion 534, a retaining recess 536 for seating the shaft's angled wall 17, a second flexible protrusion 538, and a second gap section 540 for a corner. Exemplary sections include straight line segments.

[0033] 18 shows another embodiment of a borehole 622 including shaped sections 630a, 630b, 630c, 630d. Each shaped section includes a first gap section 631 extending outside the shaft wall, a first flexible protrusion 634, a retainer 636 for seating the shaft's angled wall 17, a second flexible protrusion 638, and a second gap section for a corner 640. The gap sections are straight segments, while the flexible protrusions 634, 638 are formed by curved lines.

[0034] 19 shows another embodiment of a flexible borehole 722 including shaped sections 730a, 730b, 730c, 730d. Each shaped section includes a first curved recess 731 defining a first clearance area for a shaft corner, a first flexible protrusion 734 having a curved tip, a retention recess defined by a concave curve 736, a second flexible protrusion 738 having a curved tip, and a second curved recess 740 for the corner.

[0035] FIG. 20 shows another embodiment of a flexible borehole 822 similar to borehole 722 but having pointed flexible protrusions 834, 838.

[0036] 21 shows another flexible borehole 922 including shaped sections 930a, 930b, 930c, 930d that form clearance areas for shaft corners and retention areas for retaining rollers or other conveyor components on the shaft mounting area. Each shaped section includes a first clearance section 931 including an elongated slot formed by a curved wall transitioning to a straight wall, a first flexible protrusion 934 with a pointed tip, a retention recess defined by a concave curve 936, a second flexible protrusion 938 with a pointed tip, and a second clearance section 940 for the corner defined by a straight wall transitioning to a curved wall.

[0037] FIG. 22 shows another embodiment of a flexible borehole 1022 similar to borehole 922 but having rounded flexible protrusions 1034, 1038.

[0038] 23, a flexible borehole 1122 of a conveyor component such as a roller may include a relief opening 1180 between the flexible protrusions 1134, 1138. The relief opening 1180 provides clearance between the angled wall 17 of the shaft 12 and the wall of the flexible borehole 1122.

[0039] Although the exemplary embodiment shows a roller, the exemplary flexible hub, which includes a continuous molded section bounding a central opening and forming a gap area for accommodating a shaft corner in a first orientation and a retention feature for locking onto the shaft in a second orientation, can be used with any conveyor component designed to be attached to a shaft, such as shoes, sprockets, pulleys, position limiters, side guards, and other components known in the art.

[0040] Although the present invention has been described in detail with respect to specific versions, other versions are possible. For example, all rollers described in detail are designed for square shafts. However, the basic design can be modified to accommodate other N-sided polygonal shafts, such as triangular, pentagonal, or hexagonal. For other N-sided shafts, the inner edge is formed by a series of N molded sections matching the number of sides of the polygonal shaft. Furthermore, the exemplary roller versions are described as locking onto a shaft. However, the exemplary borehole configurations can be used to mount other shaft-mounted components, such as sprockets, pulleys, or shoes. Therefore, as these few examples suggest, the scope of the claims is not meant to be limited to the details of the exemplary versions used to illustrate the features of the present invention.

Claims

1. 1. A combination of a shaft for a conveyor system and a roller attached to the shaft, comprising: a shaft extending along a longitudinal axis and having n flat surfaces intersecting at n corners and a plurality of attachment regions, each attachment region including a beveled surface at each corner of the shaft; a roller attached to the shaft, the roller including a body having a flexible borehole defined by n shaped sections, each shaped section including a first portion forming a gap area for a corresponding corner, the first portion transitioning into a first flexible tab for accommodating the shaft by contacting a first edge of a ramp, the first flexible tab transitioning into a retaining recess, and the retaining recess transitioning into a second flexible tab for contacting a second edge of the ramp.

2. The shaft and roller combination of claim 1 , wherein said second flexible tab transitions into a gap portion that mates with said first portion.

3. 2. The shaft and roller combination of claim 1, wherein the formed section has mirror symmetry about the lowest point of the retention recess.

4. 10. The shaft and roller combination of claim 1, wherein said ramp is convexly curved.

5. 5. The shaft and roller combination of claim 4, wherein n is equal to 4, the shaft has a square cross section, and the beveled surface describes an arc of a circle having a diameter D greater than the height and width of the shaft but less than the diagonal G of the shaft.

6. 10. The shaft and roller combination of claim 1, further comprising an installation tool for rotating the shaft relative to the roller to lock the roller onto the shaft.

7. The shaft and roller combination of claim 1 , wherein said first flexible tab is rounded.

8. The shaft and roller combination of claim 1 , wherein the retention recess comprises a concave curve.

9. The shaft and roller combination of claim 1 , wherein the gap region comprises an elongated slot.

10. 2. The shaft and roller combination of claim 1, wherein the gap region includes a first concave curve extending through a 90 degree arc and a second concave curve extending through a 90 degree arc and terminating at an end point of the first concave curve.

11. The shaft and roller combination of claim 1 , wherein the formed section includes inflection points and end points aligned along line L.

12. 1. A conveyor component comprising: The main body and a flexible borehole for attaching the body to a shaft, the flexible borehole being defined by n shaped sections, each shaped section including a first gap portion, the first gap portion transitioning to a first flexible tab, the first flexible tab transitioning to a retaining recess, the retaining recess transitioning to a second flexible tab, a second gap portion identical to the first gap portion extending from the second flexible tab and terminating at a start of a successive shaped section.

13. The conveyor component of claim 12 , wherein the first flexible tab and the second flexible tab are rounded.

14. The conveyor component of claim 12 , wherein the retention recess comprises a concave curve.

15. The conveyor component of claim 12 , wherein the formed section includes inflection points and end points aligned along line L.

16. The conveyor component of claim 12 , wherein n is equal to four.

17. 1. A method of mounting a roller to a shaft in a conveyor system, comprising: aligning a corner of the shaft with a gap area in the borehole of the roller; sliding the roller along the shaft until an attachment area of ​​the shaft is within the borehole; and rotating the roller about the shaft such that a beveled surface of the attachment region of the shaft snaps into a retention feature in the borehole.

18. The method of claim 17 , wherein the rotating step includes using a mounting tool to rotate the roller relative to the shaft.

19. 18. The method of claim 17, wherein the attachment region of the shaft includes a beveled surface at each corner of the shaft, and the retention features include flexible tabs separated by retention recesses for engaging the beveled surfaces.

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