Direct drive drum for modular conveyor belts

Abstract

The direct drive drum (100) for the modular conveyor belt (180) comprises a drum rotation axis, a plurality of support elements (110), and a plurality of direct drive elements (120). Each support element (110) has a belt support surface (111) facing away from and distal to the drum rotation axis. Each direct drive element (120) is spaced apart in a circumferential direction (106) of the direct drive drum and spaced apart from each support element (110). In this way, tensions generated within the modular conveyor belt (180) and between the modular conveyor belt (180) and the direct drive drum (100) during the collapse phase of the modular conveyor belt (180) can be reduced.

Description

[Technical Field]

[0001] The present invention relates to a direct drive drum for a modular transport belt and a transport system including such a direct drive drum and a modular transport belt.

[0002] From US 2017 / 0022012 A1 and related patent application publications US 2018 / 0290833 A1 and US 2019 / 0308817 A1, a positive drive system for a spiral conveyor belt, also known as a direct drive system, is known. In such systems, a drive element—specifically, in the form of contoured ribs and cage bars forming part of a drive drum—engages with and supports a modular conveyor belt, driving the belt. The drive drum may also include a continuous circumferential ring extending between the distal ends of the ribs and the inlet end of the drum, thereby connecting the drive element and providing a belt support surface.

[0003] WO 2013 / 142136 A1 discloses a similar positive drive system in which combined drive and support elements engage, drive, and support a modular conveyor belt, with additional support elements being able to be positioned between the combined drive and support elements.

[0004] A technical problem faced by such known positive or direct drive systems when used to drive modular conveyor belts (in this context, "modular" means composed of a plurality of individual belt modules) is that they create undesirable tension in the modular conveyor belt, which prevents sufficient slippage between the drive drum and the conveyor belt. Such tension occurs particularly during changes in the direction of motion or belt travel of the modular conveyor belt.

[0005] When the direct drive drum forces the conveyor belt from a linear direction to a circular direction, i.e., a circumferential direction around the direct drive drum like a spiral conveyor system, the individual belt modules of the modular conveyor belt are forced to move toward each other toward their (inner) ends that are proximal to and supported by the direct drive drum, and away from each other toward their (outer) ends that are distal from the direct drive drum. Thus, during this "collapse phase," the distance between the individual belt modules of the conveyor belt must change, while the distance between the individual drive elements of the drive drum (which engage the conveyor belt at or between the individual belt modules) remains constant. As the individual belt modules are simultaneously forced toward and away from each other, tension is generated within the modular conveyor belt and between the modular conveyor belt and the direct drive drum.

[0006] When the modular transport belt changes its direction of travel from circular to linear during the disengagement phase, the belt modules must realign themselves to disengage from the outer surface, particularly the drive elements of the direct drive drum. This also creates tension. The tension at the exit may be too low, requiring a slight increase.

[0007] The present invention therefore aims to provide a direct drive drum that better controls the tensions that occur within the modular conveyor belt, particularly during the collapse phase of the modular conveyor belt, and more effectively also during the release phase of the modular conveyor belt.

[0008] This object is achieved by providing a direct drive drum for a modular conveyor belt according to independent claim 1 and a modular conveyor belt according to independent claim 2, which comprises such a direct drive drum. 14 This is achieved by providing a transport system according to claim 1. 16specifies a method for manufacturing a direct drive drum for a modular conveyor belt. Particularly advantageous embodiments of the invention result from the dependent claims.

[0009] The core of the invention is as follows: A direct drive drum for a modular conveyor belt comprises a drum rotation axis, a plurality of support elements, and a plurality of direct drive elements, each support element having a belt support surface distal from the drum rotation axis and facing away from the drum rotation axis. None of the direct drive elements have a belt bearing surface distal to and facing away from the drum axis of rotation. Each direct drive element is spaced apart circumferentially about the direct drive drum and spaced apart from each support element.

[0010] It has been found that tensions during the collapse phase can be reduced or even avoided by separating (in the circumferential or rotational direction of the direct drive cage or drum) the direct drive elements (e.g., comprising drive ribs) from the support elements (e.g., realized as cage bars or as additional belt support bars or sheets on the cage or cage bars) on the direct drive cage or direct drive drum of a spiral conveying system. It has therefore been found advantageous to separate the support function from the drive function (in the circumferential or rotational direction of the direct drive cage or drum) by having a first plurality of elements for performing the support function and a second plurality of elements for performing the drive function. The second plurality of elements is different from the first plurality of elements and is spatially separated from the first plurality of elements.

[0011] It has also been found that the forces transmitted from the direct drive drum to the modular conveyor belt during the release phase can be advantageously reduced and realignment of the belt modules is facilitated by separating the support function of the individual elements on the direct drive drum from the direct drive function (in the circumferential or rotational direction of the direct drive cage or drum), thereby reducing the number of direct drive elements engaging the modular conveyor belt. Reducing the number of direct drive elements engaging the modular conveyor belt reduces adhesion of the modular conveyor belt to the direct drive drum, thereby facilitating release of the modular conveyor belt from the direct drive drum.

[0012] A direct drive drum according to the present invention is a drive drum that directly or positively engages with a modular conveyor belt by pressing against at least one belt module of the modular conveyor belt, rather than simply relying on friction between the direct drive drum and at least one belt module of the modular conveyor belt.

[0013] A modular conveyor belt according to the present invention is a conveyor belt comprising (individual) belt modules, with adjacent belt modules connected to one another. In radial or spiral (modular) conveyor belts, the belt modules are interconnected in such a way that they can be relatively inverted or twisted at least to some extent in two directions perpendicular to the belt movement direction. For example, adjacent belt modules can be connected by inserting connecting ends, which are connected by a swing rod extending through a slot in the connecting end. The slot allows the swing rod to move to some extent in the belt movement direction and vice versa, thereby achieving a somewhat flexible connection. That is, the belt modules can move relative to one another to some extent.

[0014] The direct drive drum can engage with the modular conveyor belt by a direct drive element that protrudes into the free space between two adjacent belt modules of the modular conveyor belt, such a space being, for example, a gap, notch, or groove between two adjacent belt modules of the modular conveyor belt.

[0015] The free space between two adjacent belt modules may be provided between two protrusions or cams extending from the end of the belt module facing the direct drive drum and its outermost surface. The direct drive drum engages with the conveying belt by engaging with at least one of the cams extending from the belt module, for example, by pressing at least one of the cams extending from the belt module. Some cams may contact the belt support surface of the support element of the direct drive drum at certain stages. The belt module may have one or more cams, preferably one or two cams, and most preferably one cam, at the drum-facing end. The cam may be the only part of each belt module that directly contacts and is supported by the belt support surface of the support element of the direct drive drum.

[0016] A direct drive drum has a drum axis of rotation about which the direct drive drum rotates or revolves when driving the modular conveyor belt. The drum axis of rotation is a geometric or imaginary axis of rotation, a geometric intermediate axis that passes through the center of each of the (imaginary) upper and lower circular sections of the drum and extends across the entire height of the drum. For example, the axis of rotation (or axis of rotation) may not be a mechanical part or element if the direct drive drum is supported and / or driven by a turntable (e.g., primarily comprising a circumferential gear rim), a drive disk, or gears. However, a direct drive drum may have an axis of rotation in the form of a mechanical part used to support and / or drive the direct drive drum, along with one or more bearings, sprockets, and / or gears mounted on one or both ends of the axis of rotation.

[0017] The support element according to the present invention is a structural component (forming part of the surface structure of the direct drive drum) with a belt support surface directed radially outward from the drum rotation axis, thereby contacting and supporting the modular transport belt at a given time. The belt support surface may form part of the outermost surface of the direct drive drum. The support element can have various shapes, such as rectangular or rod-shaped. The length of the support element (along its longest or longitudinal axis) is several times greater than its width or diameter. For example, the length:width or length:diameter ratio is 5:1 to 100:1, preferably 10:1 to 100:1, more preferably 10:1 to 25:1. The width or diameter of the support element is typically 30 to 150 mm. The length of the support element can reach 8 m or more, depending on the height of the direct drive drum. An arrangement in which each support element extends upward (along its longitudinal axis) from a lower support end to an upper support end (so that the length of the support element defines the height of the direct drive drum or part thereof) is preferred. The support element may have one or more chamfered edges that do not function as part of the belt support surface. At a particular location along the circumference of the direct drive drum, there may be a single support element that extends entirely between the bottom and top of the direct drive drum. Alternatively, at such a location, two or more separate support elements may be provided that are aligned linearly between the bottom and top of the direct drive drum. Such separate support elements may be positioned adjacent to one another, and two adjacent support elements may be in contact with one another or may be separated by a gap or seal between them.

[0018] If the bottom of the direct drive drum does not include any support elements and / or direct drive elements used to support, engage, and drive the modular conveyor belt, but instead includes other parts such as a turntable (mainly including a circumferential gear rim), drive disk, gears, sprockets, and / or bearings, the lower support end may be at the same level as the bottom or lower end of the direct drive drum or may be near the bottom of the direct drive drum.

[0019] If the upper portion of the direct drive drum does not include any support elements and / or direct drive elements used to support, engage, and drive the modular conveyor belt, but instead includes other components such as a turntable (primarily including a circumferential gear rim), a drive disk, gears, sprockets, and / or bearings, the upper support end may be at or near the upper portion of the direct drive drum.

[0020] The direct drive element is a structural part, such as a rib, edge, or bar, that forms part of the surface structure of the direct drive drum. The structural part engages with the modular conveyor belt by temporarily inserting itself or a part of it into the free space between two adjacent belt modules, thereby functioning as a drive element. Examples of the free space include a gap, notch, or groove between two adjacent belt modules of the modular conveyor belt.

[0021] At a particular location along the circumference of the direct drive drum, there may be a single direct drive element that extends entirely between the bottom and top of the direct drive drum. Alternatively, at that location, there may be two or more separate direct drive elements aligned linearly between the bottom and top of the direct drive drum. Such separate direct drive elements may be positioned adjacent to one another. Two adjacent direct drive elements may be in contact with one another or may be separated by a gap or seal therebetween.

[0022] A simple and effective way to engage modular conveyor belts—with a view to reducing the complexity of the belt module structure and the materials and costs required for its manufacture—is to use a gap between the long sides or parts of the long sides of two adjacent belt modules, which long sides usually run crosswise or at an angle of 70° to 90° to the belt movement direction. In this case, the drive elements, such as ribs, edges, or bars, must be sufficiently narrow, i.e., their width must be small enough, or smaller than the width of the gap, so that they can be inserted (at least partially) into the gap to engage with the belt module.

[0023] The free space between two adjacent belt modules may also be provided between two protrusions or cams extending from the end of the belt module facing the direct drive element and / or the direct drive drum and / or its outermost surface, in which case the direct drive element engages with one of the protrusions or cams extending from each of the belt modules, for example by pressing the protrusion or cam, to engage with the conveyor belt.

[0024] The cams may contact the belt support surfaces of the support elements of the direct drive drum. At the drum-facing end, each belt module may have one or more cams, preferably one or two cams, most preferably one cam. The cams may be the only part of each belt module that directly contacts and is supported by one or at least one support surface of the support elements of the direct drive element.

[0025] Thus, the direct drive elements directly drive the modular conveyor belt by engaging with the belt modules, without friction or frictional force transmission. To engage with the belt modules, the direct drive elements may extend radially away from the drum rotation axis and protrude beyond the adjacent support elements. This means that the protrusion (height) of the direct drive elements exceeds at least the level of the belt support surface of the adjacent support elements, which has the advantage of direct force transmission compared to frictional force transmission with friction losses.

[0026] However, the direct drive elements need not protrude above the level of the support surfaces of the adjacent support elements over the entire height or distance between the bottom and top of the direct drive drum, or over the entire length of the direct drive elements. Rather, as mentioned above, it is advantageous for the direct drive elements to protrude only in certain portions of the direct drive drum, such as the engagement and direct drive portions, while not protruding in other portions of the direct drive drum, such as the collapse and release portions, i.e., areas where slippage or a certain amount of slippage of the modular transport belt is desired or should be tolerated to prevent (excessive) tension in the modular transport belt.

[0027] One or more distinct regions of the direct drive drum can be defined. A region of the direct drive drum is a portion of the direct drive drum that extends vertically or vertically, i.e., along and / or parallel to the drum rotation axis, over a particular portion of the height of the direct drive drum and extends entirely circumferentially around the direct drive drum; therefore, the region may more accurately be referred to as a "height" or "vertical" portion. At a particular circumferential position of the direct drive drum, the region of the direct drive drum may comprise: - a particular part or area of ​​a support element or direct drive element in the longitudinal direction of the element, when the element extends integrally from the bottom to the top of the direct drive drum or vice versa, or - one or more support elements or direct drive elements in the direction from the bottom to the top of the direct drive drum or vice versa, when using several separate elements over the full height of the direct drive drum.

[0028] Within a region of the direct drive drum, the support elements may have one or more specific characteristics that differ from the support elements in the remainder of the direct drive drum or from the support elements in at least one other region thereof. Within a region, the direct drive elements may have one or more specific characteristics that differ from the direct drive elements in the remainder of the direct drive drum or from at least one other direct drive element thereof. For example, the characteristics may be the size or dimensions (length, width, height) of the support elements and / or direct drive elements, in particular their position, such as the angle between the belt support surface and the drum rotation axis or vertical axis, and / or the height or protrusion height of the direct drive elements or their drive ribs.

[0029] In one preferred aspect of the invention, a plurality of support elements define the outermost belt support surface of the direct drive drum.

[0030] This configuration advantageously allows direct contact between the direct drive drum and the modular conveyor belt and allows for a rotationally symmetrical structure of the direct drive drum, thereby ensuring smooth driving of the modular conveyor belt by the rotation of the direct drive drum and avoiding lateral movement of the modular conveyor belt out of the belt travel direction.

[0031] The outermost belt bearing surface of the direct drive drum is the outermost drum surface that supports the modular transport belt and thus corresponds to the collectively belt bearing surfaces of the support elements.

[0032] One or more of the following structures on and / or between the support elements and the direct drive elements advantageously contribute to equalizing or evenly distributing the forces acting on the direct drive drum and / or modular conveyor belt: (i) The longitudinal axis of the support element extends along a straight or curved line from the bottom part, bottom section, or bottom end of the direct drive drum to the top part, top section, or top end of the direct drive drum. (ii) The support element extends, along a straight or curved line, together with other support elements, from the bottom, base, or lower end of the direct drive drum to the top, base, or upper end of the direct drive drum. (iii) The (longitudinal axis of) the direct drive element extends along a straight or curved line from the bottom, base, or lower end of the direct drive drum to the top, base, or upper end of the direct drive drum. (iv) The direct drive element extends, together with other drive support elements, along a straight or curved line from the bottom, base, or lower end of the direct drive drum to the top, base, or upper end of the direct drive drum. (v) The (longitudinal axis of) each direct drive element extends parallel to the (longitudinal axis of) each support element (which is behind or in front of the direct drive element in the circumferential direction of the direct drive drum). (vi) The longitudinal axis of each direct drive element extends parallel to the longitudinal axis of the straight portion of each support element (which is behind or in front of the direct drive element in the circumferential direction of the direct drive drum). (vii) The support element and the direct drive element are arranged so that the longitudinal axis of the straight portion of the support element (i.e., the portion not curved, such as the skirt portion of the direct drive drum) and the longitudinal axis of the direct drive element are arranged coaxially with the axis of rotation of the drum. (ix) the support element and the direct drive element are arranged rotationally symmetrically about the drum rotation axis; and / or (x) The plurality of support elements and the plurality of direct drive elements together form a circle or a regular polygon, the geometric center of which lies on the drum rotation axis.

[0033] Advantageously, both the support elements and the direct drive elements are arranged alternately in the circumferential direction of the direct drive drum according to the invention, with each support element being followed by 1 to 5 direct drive elements, preferably 1 direct drive element, and each direct drive element being followed by 1 to 5 support elements, preferably 1 support element.

[0034] Such an alternating arrangement of the support elements and drive elements ensures a stable and smooth way of driving the modular conveyor belt in that the modular conveyor belt is well supported and driven at the same time, thereby avoiding irregular movement of the modular conveyor belt and / or lateral movement of the modular conveyor belt outside the direction of belt movement.

[0035] The support elements and direct drive elements are advantageously arranged in the circumferential direction of the direct drive drum with a spacing between two consecutive elements, the width of which is less than or equal to the width of one of the support elements but at least as wide as one of the drive elements (so that consecutive belt modules can move relatively freely relative to one another and so that the elements can be arranged compactly to allow a compact construction of the direct drive drum).

[0036] One of the support elements may be a bar or plate and has a belt support surface distal to and facing away from the drum rotation axis, the belt support surface preferably being flat or convex. An advantage of this aspect of the invention is that the support element improves the guidance and / or support of the modular conveyor belt, whereby the flat or convex surface distributes contact or support pressure, minimizing mechanical loads or stresses acting on the modular conveyor belt, the support element itself, and the direct drive drum, and eliminating loads on the modular conveyor belt acting in a direction towards the drum rotation axis and the circumferential surface of the direct drive drum away from the direct drive element. This allows the direct drive element to be configured to more specifically engage the direct drive drum, for example by primarily comprising relatively narrow drive ribs or ridges, which serve to engage the modular conveyor belt rather than to support the modular conveyor belt or its individual modules, for example in the (narrow) gap between two modules.

[0037] One of the support elements may be configured as a bar, in particular a T-bar, a plate, or a sheet. The support element may be made of a plastic material or metal, preferably a plastic material. A plastic bar, in particular a plastic T-bar, a plastic plate, or a plastic sheet is preferred. The support element preferably features a belt support surface facing away from the drum rotation axis, in particular toward the modular conveyor belt, to support and / or guide the modular conveyor belt. The belt support surface may be made of or comprise a plastic material or metal, preferably a plastic material, while the remaining parts of the support element may be made of metal. Suitable plastic materials are, for example, wear-resistant plastic materials such as polyacetal, polycarbonate, HDPE (high-density polyethylene), polyamide, PEEK (polyetherketone), and UHMW-PE (ultra-high molecular weight polyethylene).

[0038] One of the direct drive elements may comprise a drive rib that extends radially away from the drum rotation axis and / or protrudes beyond adjacent support elements on at least a portion of the direct drive drum. An advantage of this aspect of the invention is that the direct drive element is more specifically configured for engagement with the modular conveyor belt, e.g., primarily comprising a relatively narrow drive rib, serving to engage the modular conveyor belt in, e.g., a (narrow) gap between two belt modules. In order to improve or optimize engagement with the modular conveyor belt, the direct drive element may be angled away from the drum rotation axis.

[0039] The direct drive elements, or at least their drive ribs or their surfaces, may be made of a plastic material (polymer) or metal, preferably metal, and most preferably steel. To balance durability with reduced friction and / or costs, the direct drive elements can also be advantageously made from a combination of plastic and steel. A particularly advantageous combination of materials is to use steel in the engagement section (to increase durability in the engagement section, which is exposed to high mechanical wear) and plastic further up, especially in the direct drive section (to reduce friction). The direct drive section is usually larger, or even much larger, than the engagement section in terms of the height of the direct drive drum covered by its support elements and direct drive elements. Therefore, a longer or much longer section of the modular conveyor belt is always in contact with the direct drive section rather than the engagement section. If the material of the direct drive elements is the same in both sections, greater friction occurs between the direct drive drum and the modular conveyor belt in the direct drive section than in the engagement section. The high amount of friction in the direct drive can be reduced or compensated for by using a material for the direct drive elements, or at least their drive ribs, or their surfaces, that is different from that of the engagement part, such as a plastic material, which has a lower coefficient of friction with respect to the modular conveyor belt.

[0040] In some regions of the direct drive drum, the direct drive elements may protrude completely (i.e., the full height of the ribs), partially (i.e., only a portion of the height of the ribs), or not at all beyond the adjacent support elements. In some regions of the direct drive drum, the amount of protrusion (i.e., protrusion height) may vary, i.e., increase and / or decrease.

[0041] In the case where the direct drive element protrudes beyond the adjacent support element over at least a portion of the direct drive drum, the direct drive element preferably protrudes beyond the belt support surface of the adjacent support element over at least a portion of the direct drive drum, in particular by a certain protrusion height.

[0042] The direct drive drum according to the present invention may include a lower skirt portion extending upward from the lower support end of the direct drive drum, the lower skirt portion having an upper skirt portion end at a height lower than the upper support end of the direct drive drum. In the skirt portion, the belt support surface of the support element is disposed at an angle (skirt angle, inclination angle) of 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, for example, 1° to 3.5°, relative to the drum rotation axis. The skirt angle opens downward toward the bottom of the direct drive drum. The portion of the support element extending across the skirt portion may be referred to as the skirt portion of the support element. Therefore, the skirt angle is also the angle between the belt support surface of the skirt portion of the support element and the drum rotation axis. The skirt angle may be maintained constant or may vary across the skirt portion or the skirt portion of the support element.

[0043] The advantage of having a skirt is that it facilitates the following: - Direct drive drum engages with incoming modular conveyor belt. - Bending the modular conveyor belt while it is forced from a linear motion (linear alignment) to a circular motion (circular alignment) around the direct drive drum.

[0044] Due to the skirt angle, the diameter of the direct drive drum expands across the skirt toward its base (hence the skirt is sometimes referred to as a "cone"), where (part of) the incoming modular transport belt feeds onto and reaches the direct drive drum. As the modular transport belt is forced from an essentially straight direction of motion to a curved or circular motion, i.e., bending (around the direct drive drum), bending occurs in the lateral direction (transverse or perpendicular to the direction of belt movement) and toward the direct drive drum. This requires adjacent belt modules to rotate or twist relative to each other in the lateral direction, at least to some extent. For example, adjacent belt modules may be connected by intervening link ends, which are coupled by a swing rod extending through a slot in the link end, allowing the swing rod to move to some extent in the belt movement direction and its determining direction, thereby providing a somewhat flexible connection. For example, clipping may be used as a substitute for the flexible connection of adjacent belt modules. The flexible connection allows the individual belt modules to move relative to one another to some extent, allowing the modular conveyor belt, or portions thereof, to bend and fit as closely as possible to the direct drive drum. The larger the diameter of the direct drive drum within the skirt, the greater the circumference of the direct drive drum, reducing the amount of initial bending of the modular conveyor belt at the skirt at or near the bottom of the direct drive drum compared to bending the modular conveyor belt further up on the direct drive drum, particularly compared to bending at the direct drive. The reduced bending reduces the amount of change in orientation of the individual modules of the modular conveyor belt relative to one another and also reduces the amount of tension within the modular conveyor belt between the individual modules of the modular conveyor belt and between the modular conveyor belt and the direct drive drum. The reduction in tension acting on the outermost modules is caused by the change in diameter as the belt moves upward along the skirt. The row of modules is set after engagement with the drive elements. The tension acting on the outermost links decreases as they move toward the smaller diameter, i.e., closer to one another.

[0045] The direct drive elements may extend into the skirt. This configuration provides the advantage of varying (gradually or slowly) the amount of projection or height of the direct drive elements beyond adjacent support elements according to the skirt angle. In particular, the height of the direct drive elements increases beyond adjacent support elements with increasing distance from the lower support edge and / or bottom of the direct drive drum and / or in a direction toward the top edge of the skirt. Varying the amount of projection or height of the direct drive elements beyond adjacent support elements, especially if performed gradually or slowly, has the advantage of delaying the direct drive elements, and thus the direct drive elements, until they fully engage with the modular conveyor belt. This allows the modules of the modular conveyor belt to move freely relative to one another, i.e., allows the modules to be rearranged from a linear to a circular arrangement as needed, and reduces or eliminates tension within the modular conveyor belt between the individual modules of the modular conveyor belt and between the modular conveyor belt and the direct drive drum.

[0046] Preferably, the direct drive elements project beyond the belt support surface of the adjacent support element, in particular at a projecting height.

[0047] The direct drive drum according to the present invention may comprise a collapsible portion and an adjacent engaging portion. In the collapsible portion, none of the direct drive elements protrude radially away from the drum rotation axis beyond the adjacent support element, and in the adjacent engaging portion, a protrusion of at least one direct drive element extends radially away from the drum rotation axis and beyond the adjacent support element. The collapsible portion may extend from the bottom, bottom, or lower end of the direct drive drum, or from the top, bottom, or upper end of the direct drive drum. The collapsible portion and the engaging portion may form part of a skirt portion, or may form the skirt portion if the collapsible portion extends from a lower support end of the skirt portion.

[0048] The protrusions of the direct drive elements radially away from the drum rotation axis beyond the adjacent support elements have a protrusion height that advantageously increases in a direction away from the collapsing section in at least a portion of the engagement section. This configuration of the collapsing section and the adjacent engagement section provides the advantage of (gradually or slowly) increasing the protrusion height of the direct drive elements beyond the adjacent support elements with increasing distance from the collapsing section of the direct drive drum. Within the collapsing section, the modular conveyor belt first comes into contact with the direct drive drum and begins reorienting the modules of the modular conveyor belt; i.e., the modular conveyor belt is fed into the direct drive drum (hence the collapsing section is also referred to as the "infeed section"). therefore, - there is no protrusion of the direct drive element drum at the collapsed section, and - Increasing the amount or height of protrusion of the direct drive element beyond the adjacent support element at the adjacent engagement portion of the direct drive drum, especially when carried out gradually or slowly, has the advantage of causing a delay until the direct drive element and thus the direct drive drum fully engages with the modular conveyor belt, so that the modules of the modular conveyor belt can move freely relative to each other. In this way, the belt modules can be reoriented from a linear to a circular arrangement as needed, and tension within the modular conveyor belt between the individual modules of the modular conveyor belt and between the modular conveyor belt and the direct drive drum is reduced or eliminated altogether.

[0049] In at least a portion of the engagement portion of the direct drive drum according to the invention, the protruding height of the direct drive elements decreases in the direction away from the collapsed portion. A reduction in the protruding height (above the belt bearing surface of the adjacent support element), in particular to a level where they do not protrude at all (above the belt bearing surface of the adjacent support element), has the advantage that the number of drive elements that are (fully) engaged with the modular transport belt in the circumferential direction of the direct drive drum is reduced. This allows the modules of the modular transport belt to move more relative to each other, improving reorientation and reducing tension in the modular transport belt.

[0050] Within the engagement portion, the protruding height of the direct drive element is: - only increases in the direction away from the collapsed area, - only decreases in the direction away from the collapsed area, - first increasing and then decreasing in the direction away from the collapsed area, - first decreasing, then increasing in the direction away from the collapsed area, - increase or decrease in the direction away from the collapsed part, or - at least one increase and at least one decrease in the direction away from the collapsed area.

[0051] The direct drive drum according to the present invention may comprise a direct drive section adjacent to the engagement section, in which at least one of the direct drive elements has a constant protrusion height, in the radial direction away from the drum rotation axis beyond the adjacent support element. The role of the direct drive section with the direct drive element is to fully engage with the modular conveyor belt and thereby drive it. Advantageously, the modular conveyor belt is reliably driven by a portion of the direct drive drum dedicated to the role of driving and supporting the modular conveyor belt. Preferably, the direct drive element protrudes with a constant protrusion height within the direct drive section, and the modular conveyor belt is fully and evenly engaged by the direct drive element of the direct drive section, advantageously allowing for a substantially even and uniform force transmission from the direct drive drum to the modular conveyor belt.

[0052] Preferably, the direct drive portion is located immediately above and adjacent to the engagement portion.

[0053] A direct drive drum according to the present invention may comprise an open section in which none of the direct drive elements protrude radially away from the drum rotation axis beyond the adjacent support element, in other words, a direct drive drum according to the present invention may comprise an open section in which the belt bearing surface of each support element is - protrude beyond the adjacent direct drive element or its drive rib, or - at the same level as the adjacent direct drive element or its drive rib, in particular - in the radial direction away from the drum rotation axis - at the same level as the outermost edge of the adjacent direct drive element, i.e. of the adjacent drive rib.

[0054] Due to this configuration, the direct drive elements do not engage with the modular conveyor belt in the release section. The role of the release section is to prepare the modular conveyor belt for release from the direct drive drum and, consequently, to release the modular conveyor belt from the direct drive drum. Therefore, because the direct drive elements do not protrude in the release section, none of the direct drive elements engage with the modular conveyor belt in the release section. That is, the direct drive elements do not transmit force to the modular conveyor belt (by pushing against individual modules of the modular conveyor belt). In other words, in the release section, each module of the modular conveyor belt is supported by the direct drive drum but is not engaged by a direct drive element. This advantageously facilitates the release of the modular conveyor belt from the direct drive drum and the party's ability to rearrange the modules from a circular array to a direct array.

[0055] Thus, forces transmitted from the direct drive elements to the conveyor belt during the release section are advantageously reduced, and repositioning of the belt modules is facilitated by the reduced number of direct drive elements and drive ribs engaging the modular conveyor belt. The adhesion of the modular transport belt to the direct drive drum is reduced, and therefore the release of the modular transport belt from the direct drive drum is also facilitated.

[0056] Direct drive drums according to the present invention can include an upper skirt portion. Direct drive drums can include an upper skirt portion without or in addition to a lower skirt portion. Direct drive drums can include a lower skirt portion without or in addition to a lower skirt portion.

[0057] In the upper skirt section, the belt support surface of the support element is angled (skirt angle or slope) relative to the drum axis of rotation. The skirt angle opens upward toward the top of the direct drive drum. The skirt angle or slope is 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, e.g., 1° or 3.5°, relative to the drum axis of rotation.

[0058] The upper skirt portion may be provided with collapsible portions and / or engaging portions to assist in the engagement of the modular conveyor belt which is fed directly onto the drive drum at the top and travels downward.

[0059] Alternatively, when the modular conveyor belt is running upward, the upper skirt portion may be provided with a release portion to assist in the release of the modular conveyor belt as it disengages or unwinds from the drive drum directly at the top.

[0060] In one aspect of the present invention, the upper skirt is provided with a collapsing portion and / or an engaging portion, which is supplied to the top of the direct drive drum and in particular assists in the engagement of the modular conveyor belt supplied to said upper skirt; and The lower skirt may be provided with a release portion, which assists in the release of the lower part of the direct drive drum, in particular the modular conveyor belt, which is disengaged or unwound from the lower skirt.

[0061] Conversely, in another embodiment of the present invention, The upper skirt may be provided with a release portion, which assists in the release of the upper part of the direct drive drum, in particular the modular conveyor belt, which is released or unwound from the upper skirt portion; and The lower skirt is provided with collapsible and / or engaging portions to assist the engagement of the modular conveyor belts fed to the lower part of the direct drive drum, in particular to the lower skirt.

[0062] In the case where the skirt portion is a second skirt portion and is used to assist in the release of the modular conveyor belt, the second skirt portion can have a release portion. In this case, the release effect is provided by both the release portion, in which none of the direct drive elements protrude radially away from the drum rotation axis beyond the adjacent support elements, and by the skirt angle, i.e., the angling of the belt support surfaces of the support elements, as follows: When the modular conveyor belt is released or unwound from the direct drive drum, the belt movement direction changes from a circular to a linear direction, and the individual belt modules must be reoriented and move away from the outer surface, particularly from the direct drive elements of the direct drive drum and from the support elements and their belt support surfaces. Both the realignment of the belt modules and the release from the outer surface of the direct drive drum are accompanied by a buildup of tension between the direct drive drum and the modular conveyor belt, and within the modular conveyor belt.

[0063] The process of rearranging the belt modules from an angled or curved orientation relative to one another to a straight orientation is improved and made smoother by continuously increasing the diameter of the direct drive drum at the skirt portion toward the exit portion where the modular transport belt unwinds and disengages from the direct drive drum.

[0064] Also, reducing the amount of force transmitted from the direct drive drum to the modular transport belts aids in this realignment process and the process of release from the external surface of the direct drive drum. This force reduction can be achieved by progressively separating the modular transport belts from the direct drive elements, particularly by progressively separating the modular transport belts from the drive ribs of the direct drive elements through the configuration of the drive elements, i.e., by release sections and / or through angled belt support surfaces at the skirt sections. At the same time, the size of the contact surface between the drive ribs and the modular transport belts is progressively reduced, thereby reducing adhesion to the drive ribs.

[0065] The continuous nature of this process avoids irregularities in the modular conveyor belts caused by sudden changes in the forces transmitted to the modular conveyor belts. - increased or excessive mechanical stress on the components of the modular conveyor belt, which may damage the modular conveyor belt or shorten its service life; and / or - Items and / or liquids transported by the modular conveyor belt are damaged or spilled.

[0066] A direct drive drum according to the present invention may comprise one or more, e.g. one, two, three or four, guide rails or one or more, e.g. one, two, three or four, guide frames, of which each of the one or more guide rails may form part.

[0067] The modular conveyor belt of the present invention may run on one or more guide rails, preferably two guide rails. The guide rails may be spirally wrapped around the direct drive drum and form part of a guide frame. If present, the guide rails and guide frame serve as a support for the modular conveyor belt, supporting it against gravity (from below) and may also support it laterally. If present, the guide rails and guide frame guide the modular conveyor belt around and above or below the direct drive drum. If present, the guide rails and guide frame may be fixed (e.g., by rods or sprockets) to the (cage structure of) the direct drive drum and rotate with it, or alternatively, may be fixed to a cage or scaffold and form a stationary guide frame that does not rotate with the direct drive drum.

[0068] When guide rails are used, there may be an outer guide rail and an inner guide rail, with the outer guide rail positioned farther from the drum rotation axis than the inner guide rail, and there may be one or more additional guide rails between the outer and inner guide rails.

[0069] The guide rails and / or the support surfaces independent of one another may have a special cross-sectional shape selected from the group consisting of rails in the form of (classical) rails with a smooth running surface, flat metal pieces and L-shaped profiles.

[0070] Within the aforementioned contours of the guide rails and / or support surfaces and / or in the (belt modules of) the modular conveyor belt there may be guide slots. The guide rails and guide slots in the support surfaces receive leading edges or edges protruding from the belt modules of the modular conveyor belt, while the guide slots in the (belt modules of) the modular conveyor belt receive the guide rails. The guide slots may (additionally) provide lateral guidance for the modular conveyor belt.

[0071] The L-shape may itself provide lateral guidance (by acting on the outer portion of the modular conveying belt directed away from the direct drive drum or its (circumferential) belt support surface), but for additional lateral guidance the L-shape may also be provided with guide slots.

[0072] The present invention provides a conveying system comprising a direct drive drum as described herein and a modular conveying belt as described herein.

[0073] In the transport system according to the present invention, preferably, (i) each support surface is as described herein, with at least some of the belt support surfaces being directed away from the drum axis of rotation and distal from the drum axis of rotation, supporting modular conveyor belts; and / or (ii) At least some of the direct drive elements are as described herein and engage the modular conveyor belt at the direct drive drum engagement portion and / or the direct drive portion.

[0074] The transport system is preferably a spiral transport system, where the modular transport belts describe a spiral or a helix while moving over and around the direct drive drums, or in other words, when the modular transport belts are moved over and around the direct drive drums along a line, the line describes or approximates a spiral or a spiral.

[0075] Another aspect of the present invention is a method for producing a direct drive drum for a modular conveyor belt by removing some support elements from a drum having multiple support elements and replacing each of the removed support elements with a direct drive element, thereby converting an existing drum into a direct drive drum according to the present invention.

[0076] For a better understanding of the nature and purpose of the present invention, reference numbers are provided in the following detailed description of various embodiments of the present invention, along with the accompanying drawings. Throughout the drawings, like features (machine elements or machine parts, directions, cross sections, surfaces, heights, angles, midpoints, and other geometric terms) are designated by like reference numbers, and the reference numbers used for like features in different embodiments vary by hundreds, two hundred, or even hundreds between embodiments. For example, direct drive drums are designated by the reference numbers 100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, and 4900. Support elements are designated by reference numerals 110, 510, 610, 710, 810, 910, 1010, 1110, 4510, and 4910. Direct drive elements are designated by reference numerals 120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, and 4920. Alternatively, collapse sections are designated by reference numerals 153, 553, 653, 753, 853, and 953 in various embodiments. Thus, for the sake of brevity, features that appear repeatedly in the figures are not necessarily shown in the description of every figure. They can be identified by comparing the last two digits of the reference numbers in the figures with the last two digits of the reference numbers of the first embodiment shown in Figures 1 to 10 and fully described herein, or the last two digits of the reference numbers of other embodiments.

[0077] It will be understood that the various embodiments generally and specifically described herein and illustrated in the drawings (with respect to one or more figures) are compatible with each other and therefore can be combined in accordance with the technical teachings provided herein, and one or more features of one particular embodiment and / or figure may be used in other embodiments generally or specifically described herein or illustrated in the figures.

[0078] FIG. 1 is a perspective view of a spiral conveying system with direct drive drums and modular conveying belts (schematically represented) according to one embodiment of the present invention. FIG. 2 is a plan view of the spiral conveying system of FIG. FIG. 3 is a perspective view of a direct drive of the screw conveying system of FIG. FIG. 4 is a perspective view of the lower portion of the direct drive of FIG. 3, along with a portion of the modular conveyor belt. FIG. 5 is a side view of the direct drive drum of FIG. 3, along with a portion of the modular transport belt. FIG. 6 is a perspective view of the lower part of the support element and the lower part of the direct drive element, each of which is attached to the cage of the direct drive drum of FIGS. FIG. 7 is a plan view schematically showing a part of the spiral conveying system shown in FIGS. 8 to 10 are plan views that schematically show some of the details of the spiral conveying system at different stages of engagement, as follows: FIG. 8 shows a situation where the direct drive elements of the direct drive drum are not engaged with the modular conveyor belt, for example, when the direct drive elements are within the collapsed or released portion of the direct drive drum and do not protrude beyond the adjacent support elements. FIG. 9 shows a situation where the direct drive elements of the direct drive drum are partially engaged with the modular conveyor belt, for example, when the protrusion height of the direct drive elements above the adjacent support elements changes (increases or decreases) within the engagement portion of the direct drive drum. Figure 10 shows a situation in which the direct drive elements of the direct drive drum are fully engaged with the modular conveyor belt, for example at the upper end of the skirt or direct drive of the direct drive drum, in which case the direct drive elements protrude completely beyond the adjacent support elements. FIG. 11 is a side view schematically showing the lower part of a direct drive drum according to another embodiment. FIG. 12 is a side view showing a schematic of the lower part of the support element and the lower part of the direct drive element of the lower part of the direct drive drum shown in FIG. FIG. 13 is a side view schematically showing the lower part of a direct drive drum according to yet another embodiment. FIG. 14 is a side view showing a schematic of the lower part of the support element and the lower part of the direct drive element of the lower part of the direct drive drum shown in FIG. Figures 15, 16, 17, and 19 are perspective views of the lower part of a support element and the lower part of a direct drive element according to another embodiment of the invention. Figure 17 shows the same embodiment as Figure 16, but with each element shown more broadly and from a different direction. Figures 18, 20, 21, and 22 are perspective views of the lower portion of a direct drive drum according to another embodiment of the present invention. Figure 18 shows the same embodiment as Figures 16 and 17, and Figure 20 shows the same embodiment as Figure 19. Figures 21 and 22 show an embodiment similar to that shown in Figures 19 and 20, the only difference being that the drive rib extensions on the direct drive elements in Figures 21 and 22 are different. 23-35 are perspective views of the lower portion of a direct drive drum near and including the lower support end according to another embodiment, with the configuration of the lower portion of the drive rib of each direct drive element varying from one drawing to the next. 36-47 are cross-sectional views showing various cross-sectional shapes of drive ribs of a direct drive element according to an embodiment of the present invention, each cross-sectional shape being shown from a top or bottom view of a direct drive element mounted on a direct drive drum, with the open top end (unlined) facing the drum axis of rotation while the bottom end (blunt, rounded, curved, or pointed) is either radially away from the drum axis of rotation or angled relative to that direction for purposes of engagement with a modular conveyor belt. FIG. 48 is a perspective view of the top of the direct drive shown in FIGS. 1 to 3 and 5. FIG. 49-52 are perspective views of the upper portion of a direct drive drum near and including the upper support end according to another embodiment of the present invention, with the configuration of the upper portion of the drive rib of each direct drive element varying from one drawing to the next. FIG. 53 is a side view of a spiral conveying system including a lower skirt, an upper skirt, and a guide rail. FIG. 54 is a side view of the spiral conveying system of FIG. 53, with the guide rails omitted.

[0079] 1-7, a conveying system 190 according to a first embodiment of the present invention includes a direct drive drum 100, which will be described in more detail below. The drum rotates clockwise 107a or counterclockwise 107b (as viewed from above) about a drum axis of rotation 105, as shown in FIGS. 2 and 7, thereby supporting and driving a modular conveyor belt 180. The modular conveyor belt 180 spirals or swirls while traveling upward around the direct drive drum 100 or downward around the direct drive drum 100. The modular conveyor belt 180 is fed into the direct drive drum 100 at a belt infeed section and exits the direct drive drum 100 at a belt outlet section.

[0080] In one aspect of the first embodiment of the present invention, the belt infeed section is located before the engagement section (in the direction of belt travel) and is located at or near the bottom of the direct drive drum 100, e.g., at or near point P1, while the belt exit section is located after the disengagement section (in the direction of belt travel) and is located at or near the top of the direct drive drum 100, e.g., at or near point P2. In this aspect, the modular transport belt 180 travels upward and around the direct drive drum 100 in a clockwise direction 107a, thereby describing a spiral or spiral.

[0081] In another aspect of the first embodiment of the present invention, the belt infeed section is located before the engagement section (in the direction of belt travel) and is located at or near the top of the direct drive drum 100, e.g., at or near point P2, while the belt exit section is located after the release section (in the direction of belt travel) and is located at or near the bottom of the direct drive drum 100, e.g., at or near point P1. In this aspect, the modular transport belt 180 travels downward and around the direct drive drum 100 in a counterclockwise direction 107b, thereby describing a spiral or spiral.

[0082] In all aspects of the first embodiment, such a transport system is also referred to as a spiral transport system 190.

[0083] The direct drive drum 100 includes a plurality of support elements 110 and a plurality of direct drive elements 120. These are spaced apart and spaced apart (by gaps 140) in the circumferential direction 106 of the direct drive drum 100, thereby forming a cylindrical or quasi-cylindrical outer periphery of the direct drive drum 100. Each support element 110 extends from a lower support end 101 to an upper support end 102 and has a belt support surface 111 facing distally from and away from the drum rotation axis 105. The belt support surface 111 supports a modular conveyor belt 180. Each direct drive element 120 includes a drive rib 121 that allows the modular conveyor belt 180 to engage with the drive rib 121 at the engagement portion 155 and the direct drive portion 156 of the direct drive drum 100, as particularly shown in FIG. 5 .

[0084] The lower support end 101 may be at the same level as or near the bottom of the direct drive drum. For example, if the bottom of the direct drive drum 100 is formed by a turntable or other swivel or pivoting platform to which the lower part of each support element 110 and the lower part of each direct drive element 120 (together with the lower support end 101) are attached, the lower support end 101 may be near the bottom of the direct drive drum 100. The turntable or other swivel or pivoting platform may be used to mount the direct drive drum 100 on bearings and / or to drive the direct drive drum 100 with a motor. Similarly, if the top of the direct drive drum 100 is formed by a pivot or pivoting platform to which the upper part of each support element 110 and the upper part of each direct drive element 120 (together with the upper support end 102) are attached, the upper support end 102 may be near the top of the direct drive drum 100. The swivel may be used to mount the direct drive drum 100 on bearings and / or to drive the direct drive drum 100 with a motor.

[0085] Each support element 110 extends (with its longitudinal axis) parallel to the drum rotation axis 105 and parallel to each direct drive element 120 at the upper portion of the direct drive drum 100. At the lower portion, each support element 105 has a skirt shape and is therefore designated as a skirt portion 151, as particularly shown in FIGS. 3-6. Each support element extends at an angle α relative to the vertical or drum rotation axis 105, which is a vertical axis as shown in more detail in FIG. 6. This angle α causes each support element 110, or its support surface 111, to bend or slope outward at the skirt portion 151, away from the drum rotation axis 105 as it approaches the bottom of the direct drive drum. Conversely, the direct drive drum 100 slopes from its bottom toward the skirt upper end 152. The support elements 110 and direct drive elements 120 are mounted on a cage mounting ring 170 and secured thereto by fastening means such as screws 173. Alternatively, the support elements 110 and direct drive elements 120 may be secured to the cage mounting ring 170 by welding. There is free space in the form of gaps 140 between each support element 110 and the adjacent direct drive element 120. A support element spacer 171 is disposed between each support element and each cage mounting ring 170. A drive element spacer 172 is disposed between each direct drive element 120 and each cage mounting ring 170. Consequently, the direct drive drum 100 has a substantially cylindrical shape (if the belt support surface 111 is sufficiently convex) or a quasi-cylindrical shape (if the belt support surface 111 is flat). The direct drive drum 100 also has a corresponding circumferential belt support surface 130. The support elements 110, direct drive elements 120, and cage mounting ring 170 are assembled using screws 173 and spacers 171, 172 to form a cage or cage structure. Alternative embodiments are contemplated that do not use support element spacers 171 and / or drive element spacers 172. The spacers are particularly useful in connection with the retrofitting of existing drums with multiple support elements, for example, by removing every third support element and replacing the removed support element with a direct drive element 120.

[0086] Referring to FIG. 4, the modular conveyor belt 180 includes a plurality of belt modules 182. Adjacent belt modules 182 are connected by inserting link ends connected by pivot rods extending through holes. The holes, specifically oval holes or slots, are slightly larger in diameter than the pivot rods and are present in all link ends. The holes or slots allow the pivot rods to move to some extent in and against the belt travel direction. This allows for somewhat flexible connections between the belt modules 182, making the modular conveyor belt 180 flexible in two directions, namely, up and down—as viewed in the direction of belt travel—and laterally, i.e., toward and away from the direct drive drum 100 and / or its circumferential belt support surface 130.

[0087] 2-5, the individual belt support surfaces 111 of the support elements 110 together define a circumferential belt support surface 130 of the direct drive drum 100, which supports and guides the modular conveyor belt 180. Due to the presence of the direct drive elements 120 and the gaps 140 between each support element and its adjacent direct drive element 120, the circumferential belt support surface 130 is not strictly speaking a continuous surface, but rather a partially imaginary surface, even though its position and curvature are clearly defined by the support elements 110 and their belt support surfaces 111.

[0088] 1-5, the support elements 110 and direct drive elements 120 are alternately arranged in the circumferential direction 106 of the direct drive drum, with each support element 110 followed by one direct drive element 120 and each direct drive element 120 followed by one support element 110. In alternative embodiments, each support element may be followed by two or more direct drive elements, and each direct drive element may be followed by two or more support elements. Each support element 100 is a bar, plate, or sheet and is preferably made of metal or plastic. Each support element 110 has a belt support surface 111 facing radially away from and distal to the drum axis of rotation 105, the belt support surface 111 facing the modular conveyor belt 180 for supporting the modular conveyor belt. Preferably, the support surface 111 provides additional guidance for the modular conveyor belt 180. Preferably, the support surface 111 is flat or convex. Each direct drive element 120 includes a drive rib 121 extending radially 107 away from the drum axis of rotation 105, the drive rib 121 projecting beyond the adjacent support element 110 toward the modular conveyor belt 180 for engaging and driving the modular conveyor belt 180. The drive rib 121 is provided across at least a portion 150 of the direct drive drum.

[0089] The portion 150 of the direct drive drum 100 is best seen in Figures 3-5 and extends vertically or in a vertical direction across a particular portion of the height (height or vertical portion) of the direct drive drum 100 and extends in a circumferential direction 106 around the entire circumference of the direct drive drum 100. The portion 150 is divided into an engagement portion 155 and a direct drive portion 156. In each different portion, the support elements 110 have one or more particular characteristics that are different from the support elements 110 in other portions and / or the remainder of the direct drive drum 100, and the direct drive elements 120 have one or more particular characteristics that are different from the direct drive elements 120 in other portions and / or the remainder of the direct drive drum 100. For example, this characteristic may be the size or dimensions (length, width, height) of the support element 110 and / or the direct drive element 120, in particular the angle α between the belt support surface 111 and the drum rotation axis 105 or vertical axis, as shown in Figure 6, and / or the height or protrusion height h of the direct drive element 120 or its drive ribs 121. The material may be different in different parts, for example a plastic with a low coefficient of friction in one part and a metal with a high coefficient of friction in another part.

[0090] 3 to 6, the skirt portion 151 extends upward from the lower support end 101 of the direct drive drum, with the upper skirt end 152 at a lower height than the upper support end 102 of the direct drive drum 100. In the skirt portion 151, the belt support surfaces 111 of the support elements 110 are disposed at an angle α relative to the drum rotation axis 105, the angle α being 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, e.g., 1° or 3.5°.

[0091] The skirt upper end 152 is positioned at or constituted by a kink formed in each support element 110, which is formed by bending the support element 110 outward and at an angle α (described herein) at the skirt portion 151 of the direct drive drum 100 - as viewed toward the bottom of the direct drive drum 100.

[0092] Each direct drive element 120 extends into a skirt portion 151. As best shown in FIGS. 5 and 6 , the skirt portion 151 includes a collapsing portion 153 and an engagement portion 155 adjacent and above the collapsing portion 153. At the collapsing portion 153, neither the drive element 120 nor its drive rib 121 protrudes radially away from the drum rotation axis 150 beyond the adjacent support element 110. At the engagement portion 155, the protrusion 160 of each direct drive element 120 extends radially away from the drum rotation axis beyond the adjacent support element 110, with its protrusion height h increasing in a direction away from the collapsing portion 153 and toward the skirt upper end 152. The drive rib 121 of the direct drive element 120 does not extend into the collapsing portion 153.

[0093] The increased protrusion of each drive rib 121 across the skirt 151 has the effect that the modular conveyor belt 180 does not engage the drive ribs 121 at the collapse section 153 at or near the bottom of the direct drive drum, but rather gradually engages the drive ribs 121 as the modular conveyor belt travels upward around the skirt 151 of the direct drive drum 100. This allows sufficient time for the belt modules 182 to rearrange, and if necessary, change the distance between the belt modules, when the modular conveyor belt 180 is forced to change direction during the collapse phase from a linear direction to a circular direction around the direct drive drum 100. In this way, tension in the modular conveyor belt is reduced.

[0094] The direct drive drum 100 further includes a direct drive portion 156 adjacent to and above the engagement portion 155. In the direct drive portion 156, the protruding height h of each direct drive element 120 extending beyond the adjacent support element 110 and away from the drum rotation axis 105 in the radial direction 108 is constant.

[0095] The direct drive drum 100 also includes a release section 158. In the release section 158, neither the direct drive elements 120 nor their drive ribs 121 protrude radially away from the drum rotation axis 105 beyond the adjacent support elements 110. In fact, the drive ribs 121 of the direct drive elements 120 do not extend into the release section 158. Due to this configuration, the direct drive elements 120 do not engage with the modular conveyor belts 180 in the release section 158. The role of the release section 158 is to prepare the modular conveyor belts 180 for release from the direct drive drum 100 and to ultimately release the modular conveyor belts 180 from the direct drive drum. Therefore, because the direct drive elements 120 do not protrude in the release section 158, no direct drive elements 120 engage with the modular conveyor belts 180 in the release section 158. That is, the direct drive elements 120 do not transmit force to the modular conveyor belt 180 (by pushing against the individual modules 182 of the modular conveyor belt). In other words, at the release section 158, the modular conveyor belt 180 is supported by the direct drive drum 100 but is not engaged with the direct drive elements 120. This allows for easy release of the modular conveyor belt 180 from the direct drive drum 100 and easy re-arrangement of the belt modules 182 from a circular arrangement to a linear arrangement. This reduces adhesion of the modular conveyor belt 180 to the direct drive drum 100, thus facilitating its release.

[0096] 7, the direct drive drum 100 rotates—as viewed from above—in a clockwise direction 107a about the drum rotation axis 105, thereby supporting and driving the modular conveyor belts 180, which thus travel upwardly in the clockwise direction 107a around the direct drive drum 100. The modular conveyor belts 180 are fed to the direct drive drum 100 at an infeed section 159a, where the modular conveyor belts 180 are not yet supported by (the support elements 110 of) the direct drive drum 100. The infeed section 159a is followed by a collapsing section 153, where the modular conveyor belts 180 are supported by the support elements 110 of the direct drive drum 100 in a direction towards the drum rotation axis 105, but are not yet supported by the direct drive elements 120 and their drive ribs 121. The collapse section 153 is followed by an engagement section 155, where the drive ribs 121 of the direct drive elements 120 gradually engage with the modular conveyor belt 180. Then, at a direct drive section 156, the drive ribs 121 of the direct drive elements 120 fully engage with the modular conveyor belt 180. Then, at a release section 158 (not shown in FIG. 7), the modular conveyor belt 180 is still supported by the support elements 110 but is no longer engaged with the direct drive elements 120, and finally, at an exit section 159b, the modular conveyor belt 180 disengages from the direct drive drum 100. The infeed section 159a is located at or near point P1, while the exit section 159b is located at or near point P2. In the illustrated embodiment, the angle between the infeed and outfeed is 180 degrees. Of course, other angles are possible.

[0097] In a variation of this embodiment, as previously described herein, the modular transport belt travels in the opposite direction, downward in a counterclockwise direction 107b around the direct drive drum 100. Thus, the direct drive drum 100 rotates in a counterclockwise direction 107b, with the infeed section located at or near point P2 and the exit section located at or near point P1.

[0098] Additionally, in a variation of this embodiment (not shown), the modular conveyor belt 180 travels downward in a clockwise direction 107a around the direct drive drum 100, with the infeed portion located at the top of the direct drive drum 100 and the outlet portion located at the bottom of the direct drive drum 100. Alternatively, the modular conveyor belt 180 travels upward in a counterclockwise direction 107b around the direct drive drum 100, with the infeed portion located at the bottom of the direct drive drum 100 and the outlet portion located at the top of the direct drive drum 100.

[0099] In the variant described above, as the modular conveyor belt travels between the infeed section 159a and the exit section 159b, it passes successively through other sections 153, 155, 156 corresponding to those described above in this embodiment.

[0100] The rotation angle ρ is defined as the total rotation angle of the direct drive drum 100 from the position where a particular belt module 182 begins to be supported to the position where the belt module 182 reaches a particular position on the direct drive drum 100. The rotation angle ρ is used herein to describe the position of a particular belt module 182 of the direct drive drum 100 while the belt module 182 is traveling upward around the direct drive drum, and also to describe the degree to which particular portions of the direct drive drum 100, such as the collapse portion 153, the engagement portion 155, the direct drive portion 156, and / or the release portion 158, support the belt module 182 while the belt module is traveling upward around the direct drive drum 100.

[0101] Therefore, at the position of ρ=0°, the belt module 182 begins to be supported by the direct drive drum 100, i.e., the start of the collapse section 153. Typically, at ρ=n×360°+180° (or a different angle), the belt module 182 ends its support by the direct drive drum 100 and disengages from the direct drive drum 100 at the release section 158, where n is an integer from 5 to 20 or a larger integer, preferably an integer from 5 to 15, and more preferably an integer from 8 to 12.

[0102] For example, the belt module 182 may be configured to have a size, particularly depending on the overall height of the direct drive drum 100, such as: - in the collapsed section 182 at a rotation angle ρ between 0° and 720°, preferably between 0° and 180°, most preferably between 0° and 45°; and / or at the engagement portion 155 at a rotation angle ρ of between 30° and 180°, preferably between 40° and 120°, and most preferably between 45° and 90°; - a rotation angle ρ of 75° to n×360° (where n is an integer between 1 and 100, 1 and 90, 1 and 80, 1 and 70, 1 and 60, 1 and 50, 1 and 40, 1 and 30, 1 and 20, or 1 and 10) in the direct drive 156; and / or - an additional rotation angle of at least 30°, preferably at least 40°, more preferably at least 45°, even more preferably at most 360°, and most preferably between 30° and 360° in the relief portion 158.

[0103] 8, 9, and 10, the support elements 110 and direct drive elements 120 are attached to the cage mounting ring 170 of the direct drive drum 100 using support element spacers 171 and drive element spacers 172, respectively, and using screws 173. The direct drive drum 100 supports modular conveyor belts 180 on its support elements 110, with the support surface 111 of each support element 110 contacting at least one cam 183. The cams 183 protrude from each belt module 182 of the modular conveyor belt 180 in a direction toward the drum rotation axis 105. Each support surface 111 is inclined downward and outward, away from the drum rotation axis 105. A gap 140 is present between each support element 110 and the adjacent direct drive element 120.

[0104] 8, 9 and 10 show different stages of engagement of the cams 183 of the modular transport belts 180 by the drive ribs 121 during rotation of the direct drive drum 100 as follows: FIG. 8 illustrates the situation at the collapsed section 153 or release section 158 of the direct drive drum 100, where the direct drive element 120 with the drive rib 121 does not protrude beyond the adjacent support element 110, and therefore the drive rib 121 is not engaged with the cam 183. Figure 9 illustrates the situation at the engagement portion 155 of the direct drive drum 100, where the direct drive element 120 with the drive rib 121 still protrudes a small height above the adjacent support element 110, so that the drive rib 121 is partially engaged with the cam 183. FIG. 10 illustrates the situation in the direct drive section 156 of the direct drive drum 100, where the direct drive element 120 with the drive rib 121 protrudes as far as possible beyond the adjacent support element, so that the drive rib 121 is fully engaged with the cam 183.

[0105] 11 and 12 show another embodiment of a direct drive drum 500 according to the present invention. The direct drive drum 500 comprises a direct drive element 520 with drive ribs 521 and a support element 510 with a belt support surface 111 attached to a cage mounting ring 570. The skirt portion 551 extends upward from the lower support end 501, with the skirt portion having an upper skirt end 552 at a height lower than the upper support end 502 of the direct drive drum 500. Each direct drive element 520, together with its drive rib 521, does not extend to the collapsing portion 553. The protruding portion 560 of each direct drive element 520 extends radially away from the drum rotation axis beyond the adjacent support element 510, and its protruding height h increases at the engagement portion 555 in the direction away from the collapsing portion 553. This allows the drive rib 521 itself to have a constant height.

[0106] 13 and 14 show another embodiment of a direct drive drum 600 according to the present invention. The direct drive drum 600 includes direct drive elements 620 with drive ribs 621 attached to a cage mounting ring 670, and support elements 610 with belt support surfaces 611. A skirt 651 extends upward from the lower support end 601 of the direct drive drum 600, with the skirt having an upper skirt end 652 at a height lower than the upper support end 602 of the direct drive drum 600. Each direct drive element 620, along with its drive ribs 621, extends to, but not entirely beyond, the collapsible portion 653, the lower end of which is at the same level as the lower support end 601. The protruding portion 660 of each direct drive element 620 extends radially away from the drum axis of rotation beyond the adjacent support element 610, with the protruding height h increasing at the engagement portion 655 in the direction away from the collapsible portion 653. This results in the drive ribs 621 themselves having a constant height.

[0107] FIG. 15 shows another embodiment of a direct drive drum according to the present invention. The direct drive drum includes direct drive elements 720 with drive ribs 721 attached to a cage mounting ring (not shown) and support elements 710 with belt support surfaces 711. A skirt 751 extends upward from the lower support end 701 of the direct drive drum, with the skirt having an upper skirt end 752 at a lower elevation than the upper support end of the direct drive drum. Each direct drive element 720, along with its drive ribs 721, extends to a collapsed portion 753, but the drive ribs 721 have two distinct, constant heights above the flange 726: a smaller height at a kerning or recess near or at the bottom and a larger height above the kerning. Thus, the drive rib 721 at the kerning or recess does not protrude above the adjacent belt bearing surface 711, and the drive rib 721 above the kerning or recess does protrude above the adjacent belt bearing surface 711 with the protrusion height increasing in the direction upwardly away from the kerning at the engagement portion 755. This portion of the drive rib 721 above the kerning or recess is the effective driving portion of the drive rib 721 and has a chamfer at the end 725 facing the kerning or recess to facilitate engagement of the module transport belt.

[0108] Direct drive drums according to the present invention may be embodied by varying the length and shape of the drive ribs of the direct drive elements of the direct drive drum. That is, in some embodiments, drive rib 121 (at least its drive portion) does not extend to collapsing portion 153 (FIGS. 5 and 6) and does not extend to release portion 158 (FIG. 5). In other embodiments, the effective drive portion of drive rib 721 does not extend to collapsing portion 753. In still other embodiments, drive rib 821 extends completely to collapsing portion 853, reaching its lower end at the same level as lower support end 801 (FIGS. 16-18). In other embodiments, the drive portion of drive rib 921 does not extend to collapsing portion 953 itself (FIGS. 19-22), but may extend to collapsing portion 953 via a short drive rib extension piece 923 (FIG. 21) or a long drive rib extension piece 924 (FIG. 22). These extension pieces are attached, for example, by at least two screws 973, each passing through a bore 922 in the direct drive element 920 (FIGS. 21 and 22).

[0109] As shown in FIGS. 23-35, in another embodiment of the direct drive drums 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200 according to the present invention, each direct drive element 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, and 212 0, 2220 are configured as T-bars with drive ribs 1021, 1121, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, 2221 as webs and flanges 1026, 1126, 1226, 1326, 1426, 1526, 1626, 1726, 1826, 1926, 2026, 2126, 2226. The lower portions of direct drive drums 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200, the lower portions of each direct drive element 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, and 2220, and the lower portions of drive ribs 1021, 1121, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, and 2221 form part of the skirt portion, as shown in Figures 23 to 35. In the skirt portion, the belt support surface 1011 of the support element 1010 is arranged at an angle (skirt angle, inclination angle) of 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, for example 1° or 3.5°, relative to the drum rotation axis.The lower part of each of the drive ribs 1021, 1121, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, 2221 is designed to allow optimal smooth interaction with a particular type or configuration of modular conveyor belt. 23-35 and as described below (the embodiments shown in FIGS. 23-35 differ in that, for example, support element 1010 (shown in FIGS. 23-35 but not numbered in FIGS. 23-35) and its belt support surface 1011 are the same, but the shapes of drive ribs 1021, 1121, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, 2221, and thus the overall shapes of direct drive elements 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, and—as viewed radially away from the drum rotation axis in each of FIGS. 23-35— (They are very similar to one another, differing only in their protrusion and protrusion height above adjacent belt bearing surfaces 1011.) The lower portions (and skirt portions) of the direct drive drums 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, and 2200 are referred to as the collapsed portions of the direct drive drums, and the drive ribs 1021, 1121, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, and 2221 have zero protrusion height above two adjacent belt bearing surfaces 1011.

[0110] In FIG. 23 , the drive rib 1021 has a constant height above the flange 1026 and a protrusion. The protrusion's protrusion height, in a direction radially away from the drum rotation axis above two adjacent belt support surfaces 1011, is zero at the bottom and increases upward at the skirt. Each support element 1010 extends from a lower support end 1001 that includes a belt support surface 1011. Each support element 1010 and each direct drive element 1020 is attached to the cage mounting ring 1070 using a support element spacer 1071 and a drive element spacer 1072, respectively, and using screws 1073. A gap 1040 is present between the support element 1010 and the adjacent direct drive element 1020.

[0111] In FIG. 24, the drive rib 1121 follows a vertical line with a kerning or recess near or at the bottom. The drive rib 1121 is extended to the bottom by a short drive rib extension 1123. This drive rib extension is attached to the remainder of the direct drive element 1120 by a screw 1173 and fills the aforementioned kerning (similar to the direct drive element 920, drive rib 921, and extensions 923, 924 shown in FIGS. 19-22). The drive rib 1121 and the short drive rib extension 1123 have a constant height above the flange 1126. Thus, the drive rib 1121 and the short drive rib extension 1123 have a protrusion, with a protrusion height above two adjacent belt bearing surfaces 1011 that is zero at the bottom and increases from the bottom upward at the skirt.

[0112] In Figure 25, the drive rib 1121 follows a straight line extending downward from the bottom, inclined relative to the drum rotation axis, and protrudes at an angle of 5° when viewed from below. The height of the drive rib 1121 increases at a constant gradient from the bottom upward above the flange 1226. Thus, only at a certain point does the upwardly facing drive rib 1121 have a protrusion above the two adjacent belt bearing surfaces 1011, and the height of the protrusion increases upward at the skirt.

[0113] 26, the drive rib 1321 first follows a convex curve or convex curvature extending upward from the base, and then follows a vertical line. The drive rib 1321 has a height above the flange 1326 that increases from zero at the base at a gradually decreasing slope along the curvature, and then remains constant. Thus, the drive rib 1321 protrudes above the two adjacent belt bearing surfaces 1011 only from a certain point upward, and the height of the protrusion increases upward at the skirt portion.

[0114] In Figure 27, the drive rib 1421 first follows a convex curve or convex curvature extending upward from the base, and then follows a vertical line. The drive rib 1421 has a height above the flange 1426 that increases from the base at a decreasing slope along the curvature and then remains constant. The slope at the base is much smaller, and the slope decreases more slowly than in Figure 26. Thus, the drive rib 1421 protrudes above the two adjacent belt bearing surfaces 1011 only upward from a point within the curvature, and the protruding height increases upward at the skirt.

[0115] In FIG. 28, the drive rib 1521 follows a vertical straight line with kernings or recesses near and at the bottom (similar to the direct drive elements 120, 720 shown in FIGS. 1, 3-5, and 15). The drive rib 1521 has two distinct, constant heights above the flange 1526, with a lower height at the kernings or recesses and a higher height above the kernings. Above the kernings or recesses, the drive rib 1521 has protrusions above two adjacent belt bearing surfaces 1011, with the protrusion height increasing upward from the kernings at the skirt.

[0116] In Figure 29, the drive rib 1621 follows a straight line that extends obliquely upward from below relative to the drum rotation axis, protruding at an angle of 20° when viewed from below, and then follows a straight vertical line that extends upward. The drive rib 1621 has a height above the flange 1626, and this height first increases at a constant gradient from the bottom upward and then remains constant. Therefore, the drive rib 1621 has a protrusion above the two adjacent belt support surfaces 1011 only from a certain point upward, and the protrusion height increases upward at the skirt portion.

[0117] 30, the drive rib 1721 first follows a vertical straight line upward from the bottom, then follows a straight line inclined relative to the drum rotation axis, protruding at an angle of 20° when viewed from below, and then follows a vertical straight line. The drive rib 1721 has a height above the flange 1726, which first remains constant upward from the bottom, then increases at a constant gradient, and then remains constant again. Thus, the drive rib 1721 only protrudes upward from a certain point, and its protruding height is above the two adjacent belt support surfaces 1011 and increases upward at the skirt portion.

[0118] In Figure 31, the drive rib 1821 begins some distance upward from the bottom, follows a line inclined relative to the drum rotation axis, extends at a 20° angle as viewed from below, and then follows a vertical line. The drive rib 1821 has a height above the flange 1826 that is minimum zero from the bottom upward, then jumps to a value, from which it increases at a constant slope and remains constant. Thus, the drive rib 1821 only projects above the two adjacent belt bearing surfaces 1011 from a certain point upward, and its projected height increases upward at the skirt portion.

[0119] 32, the drive rib 1921 begins only some distance upward from the bottom, follows a convex curve or convex curvature extending upward from the flange 1926, and then follows an upward straight line. The drive rib 1921 has a height above the flange 1926 that increases from zero at a decreasing slope along the curvature and then remains constant. Thus, only from a point above the curvature does the drive rib 1921 have a projection above the two adjacent belt bearing surfaces 1011, and the projection height increases upward at the skirt.

[0120] 33, the drive rib 2021 follows a straight line, which is inclined at an angle toward the drum rotation axis, and this angle is preferably the same as the angle at which the belt support surface 1011 is inclined toward the drum rotation axis (skirt angle, inclination angle), i.e., 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, for example 1° or 3.5°. The drive rib 2021 has a height above the flange 2026, which height decreases from the bottom upward at a constant gradient. Thus, the drive rib 2021 has a protrusion above the two adjacent belt support surfaces 1011, and the protrusion height remains constant at the skirt portion.

[0121] 34, the drive rib 2121 begins a distance upward from the bottom and follows a straight vertical line. The drive rib 2121 has a constant height above the flange 2126. Thus, the drive rib 2121 has a protrusion above the two adjacent belt bearing surfaces 1011, and the protrusion height increases upward at the skirt.

[0122] In FIG. 35 , the drive rib 2221 first follows a vertical line extending upward from the bottom, then follows a line inclined toward the drum rotation axis at a certain angle when viewed from below, and finally follows a vertical line again. This angle is between 1° and 45°, preferably between 10° and 45°, more preferably between 10° and 35°, and most preferably between 15° and 30°, e.g., 20°. The drive rib 2221 has a height above the flange 2226 that is first constant from the bottom upward, then decreases at a constant gradient further upward, and then remains constant further upward. Thus, the drive rib 2221 has protrusions above the two adjacent belt support surfaces 1011, and the protrusion height increases from the bottom upward at the skirt portion and then decreases until the protrusion disappears at the skirt portion.

[0123] 36-47, the drive ribs of the direct drive elements of the direct drive drum of the present invention are embodied in a variety of cross-sectional shapes 3327, 3427, 3527, 3627, 3827, 3927, 4027, 4127, 4227, 4327, and 4427 to accommodate a particular type or configuration of modular conveyor belt and enable optimized smooth interaction. Each cross-sectional shape 3327, 3427, 3527, 3627, 3827, 3927, 4027, 4127, 4227, 4327, and 4427 is viewed from the upper or lower end of the direct drive element attached to the direct drive drum. The open top end (not outlined) faces the drum axis of rotation, while the bottom end (which may be straight, rounded, curved, or pointed) is directed radially away from or angled relative to the drum axis of rotation for engagement with the modular transport belts. The bottom end is therefore also referred to herein as the outer end. Thus, in another embodiment of the invention, the drive rib has a cross-sectional shape (extending perpendicular to its longitudinal axis, i.e., as viewed from one end of the drive rib or directly from the top or bottom of the drive drum) as shown in Figures 36-47, as follows: FIG. 36 shows a rectangular shape 3327. FIG. 37 shows a rectangular shape 3427 with rounded outer edges. FIG. 38 shows a rectangular shape 3527 whose outer edges are pointed at 90° angles like an isosceles triangle. FIG. 39 shows a rectangular shape 3627 whose outer edges are pointed at a 30° angle like an isosceles triangle. FIG. 40 shows a rectangular shape 3727 whose outer ends are pointed at a 25° angle like an isosceles triangle, resulting in a rounded tip. FIG. 41 shows a rectangular shape 3827 in which the outer edge is pointed at a 22.5° angle, with only one of the long sides of the rectangle being angled. FIG. 42 shows a rectangular shape 3927 in which the outer edge is pointed at a 22.5° angle and only one of the long sides of the rectangle is angled, resulting in a rounded tip. FIG. 43 shows a cube or bar-shaped profile 4027 in which one of the edges is chamfered away from the outer end. FIG. 44 shows a rectangular shape 4127 in which one of the outer corners is rounded with a radius of curvature equal to half the width of the rectangular shape 4127 (0.5). FIG. 45 shows a rectangular shape 4227 in which one of the outer corners is rounded with a radius of curvature equal to the width of the rectangular shape 4227. Figure 46 shows a rectangular shape 4327 where at one point the rectangle is angled laterally at an angle of 1° to 45°, preferably 10° to 45°, more preferably 10° to 35°, most preferably 10° to 30°, for example 15°. FIG. 47 shows a rectangular shape 4427 that is bent laterally from a point along a curve around the circumference of the direct drive drum, the radius of curvature of the curve being equal to eight times the width of the shape.

[0124] FIG. 48 shows the upper portion of the direct drive drum 100 of FIGS. 1-10 in greater detail.

[0125] 49-52 show different embodiments of the upper portions of direct drive drums 4500, 4600, 4700, 4800 according to the present invention, including the upper portion of direct drive section 156 and the upper open section 158, and in particular the upper portions of its direct drive elements 4520, 4620, 4720, 4820 and its drive ribs 4521, 4621, 4721, 4821. In the open section, the height of the drive ribs 4521, 4621, 4721, 4821 above the flanges 4526, 4626, 4726, 4826, respectively, is reduced, and therefore the protruding height of the drive ribs 4521, 4621, 4721, 4821 above the two adjacent belt bearing surfaces 4511 is reduced or zero.

[0126] FIG. 49 shows the top of the direct drive drum 4500, along with the top of the support element 4510 and the top of the direct drive element 4520. The top of the support element 4510 has a belt support surface 4511 and extends to an upper support end 4502. The top of the direct drive element 4520 is in the form of a T-bar with a drive rib 4521 as a web and a flange 4526. The top of the direct drive element 4520 is attached to a cage mounting ring 4570 using screws 4573, with a drive element spacer 4570 positioned between the direct drive element 4520 and the cage mounting ring 4570. The drive rib 4521 follows a vertical straight line upward. The drive rib 4521 has a recess from which it continues to follow a vertical straight line to the top, where it still protrudes from the flange 4526. The drive rib 4521 has two different constant heights above the flange 4526, a smaller height at the recess and a larger height below the recess. Thus, the drive rib 4521 has a protrusion above the two adjacent belt bearing surfaces 4511. The protrusion height is constant below the recess. Also, the drive rib 4521 has no protrusion above the recess.

[0127] 50, the drive rib 4621 first follows a vertical straight line upward, then follows a straight line that, when viewed from below, is inclined at an angle toward the drum rotation axis to reach the top, where it still protrudes from the flange 4626. The angle is between 1° and 45°, preferably between 10° and 45°, more preferably between 10° and 35°, and most preferably between 10° and 30°, for example 10°. The drive rib 4621 has a height above the flange 4626 that first remains constant and then steadily decreases further upward, from a certain point to the top, there is no protrusion.

[0128] 51, the drive rib 4721 first follows an upward vertical line and then follows a convex curve or curvature upward to the apex. The drive rib 4721 has a height above the flange 4726 that is initially constant and then decreases upward at an increasing slope along the curvature. Thus, the drive rib 4721 has a protrusion above two adjacent belt bearing surfaces 4511 that is initially constant and then decreases upward at an increasing slope until it reaches the apex, at which point it no longer protrudes.

[0129] 52, the drive rib 4821 first follows a vertical straight line and then follows a convex curve or curvature upward to the apex. The drive rib 4821 has a height above the flange 4826 that is first held constant and then decreases at a decreasing rate along the curvature. Thus, the drive rib 4821 has a protrusion above the two intersecting belt support surfaces 4511 that is first held constant and then decreases at a decreasing rate upward until it reaches the apex, at which point it no longer protrudes.

[0130] 53 and 54 each have generally the same structure as the direct drive drum 100 shown in FIGS. 1 to 10, with the following exceptions. - the configuration of its upper part, if the direct drive drum 4900 additionally comprises an upper skirt part 4957 (in addition to the lower skirt part 4951), and - in the case of Figure 53, guide rails 4995, 4996 and any guide frame (not shown) of which said guide rails 4995, 4996 form part.

[0131] The direct drive drum 4900 thus comprises a plurality of support elements 4910 and a plurality of direct drive elements 4920, both of which are fixed to the cage mounting ring 4970 by screws 4973 and are separated from one another and spaced a distance from one another (created by gaps 4940) in the circumferential direction 4906 of the direct drive drum 4900, thus forming a cylindrical or quasi-cylindrical periphery of the direct drive drum 4900. Each support element 4910 extends from a lower support end 4901 to an upper support end 4902 and is positioned distally from and facing away from the drum rotation axis (not shown, but positioned at a position corresponding to the position of the drum rotation axis 105 shown in FIGS. 2 and 7 ). The belt support surface 4911 supports the modular transport belt 4980. Each direct drive element 4920 includes a drive rib 4921 with which the modular transport belts 4980 engage in the same manner as described herein in connection with Figures 1-10. Thus, except for the inclusion of the second or upper skirt portion 4957, the direct drive drum 4900 functions in the same manner as the direct drive drum 100, and the description in Figures 1-10 and herein is also applicable to the direct drive drum 4900. The reference numbers in Figures 53 and 54, although ending with the same two digits, differ in the hundreds and thousands digits from the reference numbers used in Figures 1-10, and have the same meaning as described herein in connection with Figures 1-10.

[0132] In the upper skirt portion 4957, each support element 4910 and its belt support surface 4911 is angled or tilted away from the drum axis of rotation (not shown in FIGS. 53 and 54 , but by analogy with the illustration in FIG. 6 ) toward the direct drive drum 4900. In the upper skirt portion 4957, the direct drive drum 4900 flares toward the upper skirt end, in this case the upper support end 4902. The skirt angle or tilt angle α is 0.5° to 30°, preferably 0.5° to 15°, more preferably 0.5° to 10°, even more preferably 0.5° to 7.5°, and most preferably 0.5° to 5°, e.g., 1° or 3.5°, relative to the drum axis of rotation.

[0133] The upper skirt portion 4957 may include a release portion and is provided in addition to the lower skirt portion 4951. The upper skirt portion 4957 assists in the release of the modular transport belt 4980 from the direct drive drum 4900 when the modular transport belt 4980 is fed to the direct drive drum 4900 and engaged by its direct drive elements 4920 at the lower skirt portion 4951, which includes a collapsing portion and an engagement portion, and runs upward around the direct drive drum 4900.

[0134] Conversely, the modular transport belt 4980 can be fed to the direct drive drum 4900 and engaged by its direct drive elements 4920 at the upper skirt portion 4957. In this case, the upper skirt portion includes a collapsing portion and an engaging portion and runs downwardly around the direct drive drum, and the lower skirt portion 4951 includes a releasing portion to assist in disengaging or unwinding the modular belt 4980 from the direct drive drum 4900.

[0135] The second skirt portions 4951, 4957 are used to assist in the release of the modular transport belt 4980, and the second skirt portions 4951, 4957 comprise release portions. In this case, the release-assist effect is provided by both the configuration of the release portions, i.e., the drive ribs 4921 as described herein, and the angling of the skirt portions, i.e., the support elements 4910 and their belt support surfaces 4911 as described herein.

[0136] The modular transport belt of the present invention may run on one or more guide rails, preferably two. The guide rails 4995, 4996 shown in FIG. 53 may be spirally wrapped around the direct drive drum and form part of a guide frame (not shown). The guide rails 4995, 4996 and guide frame, if present, serve as supports for the modular transport belt, supporting the modular transport belt against gravity (from below) and may also support it laterally. The guide rails 4995, 4996 and guide frame, if present, may be fixed to the direct drive drum 4900 (cage structure) and rotate with the direct drive drum 4900 (e.g., by rods or sprockets, not shown), or alternatively, may be fixed to a cage or scaffolding and form a stationary guide frame (not shown) that does not rotate with the direct drive drum 4900.

[0137] There is an outer guide rail 4995 and an inner guide rail 4996, with the outer guide rail 4995 being positioned further away from the drum rotation axis than the inner guide rail 4996. There may be one or more additional guide rails (not shown) between the outer and inner guide rails. The independent guide rails 4995, 4996 may have a particular cross-sectional shape selected from the group consisting of a rail in the form of a (classical) rail with a smooth running surface, a flat metal piece, and an L-shape.

[0138] The aforementioned cross-sectional shape of the guide rail and / or the (belt modules of) the modular conveyor belt may have guide slots, which receive the leading edges or edges of the belt modules of the modular conveyor belt and / or the guide slots of the (belt modules of) the modular conveyor belt receive the guide rails, which (additionally) also guide the modular conveyor belt laterally.

[0139] The L-shape solely provides lateral guidance (by acting on) the outer portion of the modular conveyor belt facing away from the direct drive drum or (circumferential) belt support surface, but the L-shape may also be provided with guide slots for additional lateral guidance.

[0140] 1, 3-6, and 11-35, these figures illustrate further embodiments by turning them upside down, e.g., so that upper skirt ends 152, 552, 652, 752, 852, 952 become lower skirt ends, and interpreting and applying the description provided herein in the same manner. That is, skirt portions 151, 551, 651, 751, 851, 951 as upper skirt portions are disposed on top of direct drive drums 100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, and modular conveyor belt 180 is mounted on the top and upper skirt portions of direct drive drums 100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200. 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, and below which they are released and disengaged from the direct drive drums 100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200.

Claims

1. A drum rotation shaft (105), a plurality of support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) having belt support surfaces (111, 511, 611, 711, 811, 911, 1011, 4511, 4911) facing away from the drum rotation axis (105) distally from the drum rotation axis (105); Multiple direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) and A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) for a modular conveyor belt (180, 4980), comprising: none of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) have a belt bearing surface distal to the drum rotation axis; each direct drive element is spaced apart in a circumferential direction (106, 4906) of the direct drive drum and spaced apart from each support element; A direct drive drum.

2. 2. The direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) of claim 1, the plurality of support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) defining an outermost belt support surface (130) of the direct drive drum; A direct drive drum.

3. 3. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200) according to claim 1 or 2, Both the support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) and the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) are arranged in a circumferential direction (106, 4906), each support element followed by one to five direct drive elements, and each direct drive element followed by one to five support elements; A direct drive drum.

4. 4. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to any one of claims 1 to 3, Each support element (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) of the plurality of support elements is a bar or a plate; A direct drive drum.

5. 5. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4900) according to any one of claims 1 to 4, Each direct drive element (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) of the plurality of direct drive elements is driven by a drive rib (121, 521, 621, 721, 821, 921, 1021, 1221, 1321, 1421, 1521, 1621, 1721, 1821, 1921, 2021, 2121, 2221, 4521, 4621, 4721, 4821, 4921), the drive ribs extend radially (108) from the drum axis of rotation (105) and / or project beyond adjacent support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) across at least a portion (150) of the direct drive drum; A direct drive drum.

6. 6. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to any one of claims 1 to 5, a lower skirt portion (151, 551, 651, 751, 851, 951, 4951) extending upward from a lower support end (101, 501, 601, 701, 801, 901, 1001, 4901); the lower skirt portion has an upper skirt end (152, 552, 652, 752, 852, 952, 4952) at a height lower than an upper support end (102, 502, 602, 4502, 4902) of the direct drive drum; the belt support surfaces (111, 511, 611, 711, 811, 911, 1011, 4511, 4911) of the support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) at the lower skirt are arranged at an angle (α) of 0.5° to 30° relative to the drum rotation axis (105); A direct drive drum.

7. 7. The direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) of claim 6, at least some of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) extend within the lower skirt portion (151, 551, 651, 751, 851, 951, 4951); A direct drive drum.

8. 8. A direct drive drum (4900) according to any one of claims 1 to 7, comprising: an upper skirt portion (4957) extending downward from the upper support end (4902) of the direct drive drum; In the upper skirt portion, the belt support surface (4911) of the support element (4910) is disposed at an angle of 0.5° to 30° with respect to the drum rotation axis. A direct drive drum.

9. 9. The direct drive drum (4900) of claim 8, At least some of the direct drive elements (4920) extend within the upper skirt portion (4957); A direct drive drum.

10. 10. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to any one of claims 1 to 9, a collapsing portion (153, 553, 653, 753, 853, 953) and an adjacent engaging portion (155, 555, 655, 755, 855, 955); in the collapsed portion, none of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) protrudes in the radial direction (108) away from the drum rotation axis (105) beyond an adjacent support element (110, 510, 610, 710, 810, 910, 1010, 4510, 4910); At the engagement portion, a protrusion (160, 560, 660) of at least one of the direct drive elements extends radially away from the drum rotation axis and beyond an adjacent support element. A direct drive drum.

11. 11. The direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) of claim 10, the protrusion (160, 560, 660) of at least one of the direct drive elements, which protrudes radially away from the drum rotation axis and beyond an adjacent support element, has a protrusion height (h); the protrusion height increases in a direction away from the collapsing portion at least in a portion of the engagement portion (155, 555, 655, 755, 855, 955) and / or decreases in a direction away from the collapsing portion (153, 553, 653, 753, 853, 953) at least in a portion of the engagement portion (155, 555, 655, 755, 855, 955), A direct drive drum.

12. 12. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to claim 10 or 11, the direct drive drum includes a direct drive portion (156) adjacent to the engagement portion; In the direct drive section, a protruding height (h) of at least one of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) protruding in the radial direction (108) away from the drum rotation axis (105) and beyond an adjacent support element (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) has a constant protruding height (h); A direct drive drum.

13. 13. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to any one of claims 1 to 12, the direct drive drum has a release portion (158); In the open portion, none of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) protrudes beyond an adjacent support element (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) in the radial direction (108) away from the drum rotation axis (105); A direct drive drum.

14. A direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) according to any one of claims 1 to 13; Modular conveyor belt (180, 4980) and A transport system (190).

15. 15. A transport system (190) according to claim 14, comprising: (i) at least some of the belt support surfaces (111, 511, 611, 711, 811, 911, 1011, 4511, 4911) of the support elements (110, 510, 610, 710, 810, 910, 1010, 4510, 4910) support the modular conveyor belt (180, 4980); and / or (ii) at least some of the direct drive elements (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920) are connected to the direct drive drums (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) engaged with the engagement portion (155, 555, 655, 755, 855, 955) and / or the direct drive portion (156); A transport system comprising:

16. 14. A method for manufacturing a direct drive drum (100, 500, 600, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2100, 2200, 4500, 4600, 4700, 4800, 4900) for a modular conveying belt (180, 4980) according to any one of claims 1 to 13, comprising: removing some support elements from a drum having a plurality of support elements and replacing each removed support element with a direct drive element (120, 520, 620, 720, 820, 920, 1020, 1120, 1220, 1320, 1420, 1520, 1620, 1720, 1820, 1920, 2020, 2120, 2220, 4520, 4620, 4720, 4820, 4920); A method for manufacturing a direct drive drum.

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