Roller belt sorter with booster

Abstract

A sorting conveyor system (46) includes a main conveyor line (48) intersected by a cross conveyor (18) having a roller-top conveyor belt (20). The roller-top conveyor belt, which can be driven bidirectionally perpendicular to the conveying direction of the main conveyor line, has article-supporting belt rollers (22) that can freely rotate in the main conveying direction (14). Articles (38) fed from the main conveying line onto the cross conveyor can be sorted left or right by the conveyor belt. Articles destined for downstream sorting pass over the roller-top conveyor belt, which rests on the freely rotatable belt rollers, and return to the main conveyor line. A booster (40), such as a motorized roller (40) between the main conveyor line and the cross conveyor, applies a force in the main conveying direction to articles destined to cross the cross conveyor.

Description

[Technical Field]

[0001] FIELD OF THE INVENTION The present invention relates generally to power driven conveyors, and more particularly to sorters that use roller-top belts.

[0002] In the tire industry, finished tires leave an inspection station in various types and sizes. The tires are then sorted for different destinations based on size and type. This is accomplished by interrupting a main conveyor with one or more cross conveyors. Each cross conveyor includes a bidirectional lateral roller-top belt that can sort left or right with a bidirectionally driven belt, or cross the belt and return onto the main conveyor for further sorting downstream. One example of such a sorting system is described in U.S. Pat. No. 7,306,086, issued Dec. 11, 2007, to Henk W.M. Boelaars. The conveyor system described in that patent requires the roller-top belt to be raised and lowered depending on the tire's assigned destination. To sort tires to the right or left, the roller-top belt is raised above the level of the main conveyor. The roller-top belt is lowered for tires not diverted by the cross conveyor. The inertia of the tire entering the cross conveyor is sufficient to push the tire over the roller-top belt onto the next main conveyor segment, allowing the tire to be transported downstream. However, if the cross conveyor is much wider than the diameter of the tire, the inertia of the tire may not be great enough to force the tire over the cross conveyor. Summary of the Invention

[0003] One version of the sorting system includes an infeed conveyor that advances articles in a first direction from an entrance to an exit, a cross conveyor, and first, second, and third destinations for the articles. The cross conveyor includes a roller-top conveyor belt having a first side and an opposite second side spaced apart in the first direction, and a first end and an opposite second end. The roller-top conveyor belt is arranged to selectively move in a second direction perpendicular to the first direction or in a third direction opposite the second direction. Article-supporting belt rollers within the roller-top belt are freely rotatable in the first direction. The first destination is positioned on the second side of the roller-top conveyor belt opposite the infeed conveyor to receive articles passing over the roller-top conveyor belt in the first direction. A second destination is positioned at a first end of the roller-top conveyor belt to receive articles discharged from the first end of the roller-top conveyor belt advancing in a second direction. A third destination is positioned at a second end of the roller-top conveyor belt to receive articles discharged from the second end of the roller-top conveyor belt to receive articles discharged from the second end of the roller-top conveyor belt advancing in a third direction. A booster disposed between the outlet of the first conveyor and the first side of the cross conveyor is selectively operable to apply a force in a first direction to selected articles exiting the infeed conveyor to push the selected articles across the width of the roller-top conveyor belt to the first destination.

[0004] Another version of the sorting conveyor includes a main conveyor line including a series of main conveyor segments that advance articles in a first direction from the entrance to the exit of each main conveyor segment, and multiple cross conveyors that intersect the main conveyor line between the main conveyor segments. Each cross conveyor includes a roller-top conveyor belt. The roller-top conveyor belt has a first side and an opposite second side spaced apart in the first direction, and a first end and an opposite second end. The roller-top conveyor belt is arranged to selectively move in a second direction perpendicular to the first direction or a third direction opposite the second direction. The article support belt rollers are freely rotatable in the first direction. A first destination receives articles at the first end of the roller-top conveyor belt that are discharged from the first end of the roller-top conveyor belt advancing in the second direction. The second destination receives articles discharged from the second end of the roller-top conveyor belt advancing in a third direction at the second end of the roller-top conveyor belt. A booster disposed between the outlet of each main conveyor segment and a first side of each cross conveyor intersecting the main conveyor line and selectively operable to apply a force in a first direction to selected articles exiting each main conveyor segment to push the selected articles across the width of the roller-top conveyor belt to the entrance of the next main conveyor segment in the main conveyor line. [Brief explanation of the drawings]

[0005] [Figure 1] FIG. 1 is an isometric view of the sorting section of a sorting conveyor using a bidirectional roller top cross conveyor belt with assist rollers. [Figure 2] FIG. 2 is a top view of the sorting section of the sorting conveyor of FIG. 1. [Figure 3] FIG. 2 is a side view of the sorting section of the sorting conveyor of FIG. 1. [Figure 4] FIG. 2 is a top view of a sorting conveyor including a series of sorting sections such as those of FIG. 1. [Figure 5]FIG. 4 is a side view of the sorting section as in FIG. 3, but with linear motor driven rollers instead of assist rollers. [Figure 6] FIG. 4 is a side view of the sorting section as in FIG. 3 but with air manifolds instead of assist rollers. DETAILED DESCRIPTION OF THE INVENTION

[0006] A sorting conveyor embodying features of the present invention is shown in Figures 1-3. Conveyor 10 includes an infeed conveyor 12, which may be, for example, a conveyor belt or a roller conveyor. Infeed conveyor 12 transports articles, such as tires, in a first, or main, conveying direction 14. Infeed conveyor 12 extends in length in the conveying direction from an inlet 16 to an outlet 17. Infeed conveyor 12 feeds the articles onto a cross conveyor 18, which includes a roller-top conveyor belt 20, such as an INTRALOX® Series 4400 TRT (Transverse Roller Top) conveyor belt manufactured and sold by Intralox, LLC of Harahan, Louisiana, USA.

[0007] The roller-top conveyor belt 20 has article-supporting rollers 22 on its outer surface. The belt rollers are freely rotatable on axes 24 that are perpendicular to the first conveying direction 14. In this manner, the belt rollers 22 can freely rotate in the first direction. The roller-top conveyor belt 20 is driven bidirectionally, to the left in a second direction 26 and to the right in a third direction 27, by a drive 28 that may include, for example, a motor, gearbox, drive shaft, and drive sprocket. The second and third directions 26, 27 are perpendicular to the first conveying direction 14. The roller-top belt 20 has a length that extends from a first end 30 to an opposite second end 31 and a width that extends from a first side 32 to an opposite second side 33.

[0008] The cross conveyor 18 facilitates sorting of articles received from the infeed conveyor 12 to a selected one of three destinations: (1) directly over the roller-top conveyor belt 20 to the outfeed conveyor 34, (2) left to a left destination 36, or (3) right to a right destination 37. The left and right destinations 36, 37 may be implemented, for example, as discharge conveyors, chutes, or collection tables. A cross conveyor drive 28 selectively drives the roller-top conveyor belt in a second direction 26 to the left destination 36 or in a third direction 27 to the right destination 37, depending on the destination assigned to the article. Articles not assigned to a left or right destination pass over the freely rotatable rollers 22 and over the roller-top conveyor belt 20 to the outfeed conveyor 34. When an article, such as a tire 38, is directed toward the outfeed conveyor 34, the roller-top conveyor belt 20 is stopped, allowing the article to coast over the freely rotatable rollers 22 and onto the outfeed conveyor 34 at the exit 17 of the infeed conveyor 14. A position sensor 39 near the exit 17 detects the presence of the article.

[0009] Because the roller-top conveyor belt 20 may be wide or articles may not have sufficient inertia to exit the infeed conveyor 12 and cross the cross conveyor 18, a booster in the form of a power-assisted roller 40 is positioned in the gap 41 between the infeed conveyor exit 17 and the upstream near first side 32 of the roller-top conveyor belt. The booster 40 is selectively operable to apply a force in a first direction to selected articles exiting the infeed conveyor 12 to help push the articles across the width of the cross conveyor 18 and onto the outfeed conveyor 34. The power-assisted roller 40 is driven by a roller drive 42 that is independent of the infeed drive 44 of the infeed conveyor 12. The speed of the power-assisted roller 40 is sufficiently great to ensure that the inertia of articles destined to cross the cross conveyor 18 is sufficient to complete the crossing. If an article is assigned to the left destination 36 or the right destination 37, the speed of the powered roller 40 can be adjusted to a speed below that of the infeed conveyor 12 to slow the article so that it does not overshoot the cross conveyor. The roller-top conveyor belt 20 can be stopped or moved while articles destined for the left or right destinations 36, 37 are transferred onto the cross conveyor 18. As one alternative, the powered roller drive 42 can include a clutch that is engaged to propel the article across the cross conveyor and disengaged for articles exiting the infeed conveyor 12 that are assigned to the left destination 36 or the right destination 37. As another alternative, the powered roller 40 can be slaved to the infeed conveyor drive 44 by, for example, a drive belt or chain, pulleys or sprockets, and a clutch.

[0010] A longer conveyor system 46 including multiple cross conveyors 18 and sorting destinations is shown in Figure 4. The main conveyor line 48 includes a series of main conveyor segments 50, such as the infeed and outfeed conveyors 12, 34 of Figures 1-3. Like the infeed conveyor 12 and outfeed conveyor 34 of Figures 1-3, all of the main conveyor segments 50 are aligned in the main transport direction 14. The main conveyor line 48 is intersected by cross conveyors 18, each serving a sorting destination 36, 37 on either side.

[0011] A different type of booster is shown in Figure 5. This booster 52 is realized as a series of small diameter rollers 54 comprising magnetic or steel material. A linear motor stator 56 below the rollers 54 generates an electromagnetic wave that rotates the rollers 54 and pushes articles in the first conveying direction 14 across the cross conveyor 18 onto the outfeed conveyor 34. The rollers 54 with magnetic material form a linear synchronous motor with the stator 56, while the rollers with steel material form a linear induction motor with the stator.

[0012] Another alternative booster is shown in Figure 6. This booster is realized as an air manifold 58 supplied with pressurized air by an air source 60. An outlet at the top of the manifold directs air jets 62 at articles exiting the infeed conveyor 12. The air jets apply a force component in the first conveying direction 14 to help push selected articles over the belt rollers 22 on the stopped roller-top belt 20 and onto the outfeed conveyor 34.

[0013] The speeds of the drives 28 of the cross conveyor 18, the drives 44 of the main conveyor segment 50, and the drives 42 of the boosters 40 are conventionally controlled by a processor (not shown). Position sensors 39 along the length of the conveyor system report the position of the articles to the processor. Identification sensors, such as bar code readers, also provide the processor with the identity of each of the articles, thereby enabling the processor to determine the assigned destination of each article and control the sorting system accordingly.

Claims

1. 1. A sorting system comprising: an infeed conveyor that advances the articles in a first direction from an inlet to an outlet; A cross conveyor, a first side and an opposite second side spaced apart in the first direction; 1. A roller-top conveyor belt having a first end and an opposite second end, a roller-top conveyor belt arranged to selectively move in a second direction perpendicular to the first direction or in a third direction opposite the second direction; a cross conveyor including a plurality of article supporting belt rollers freely rotatable in the first direction; a first destination positioned on the second side of the roller-top conveyor belt opposite the in-feed conveyor for receiving articles passing over the article support belt rollers across the roller-top conveyor belt in the first direction; a second destination at the first end of the roller-top conveyor belt for receiving articles discharged from the first end of the roller-top conveyor belt advancing in the second direction; a third destination at the second end of the roller-top conveyor belt for receiving articles discharged from the second end of the roller-top conveyor belt advancing in the third direction; and a booster disposed between the outlet of the infeed conveyor and the first side of the cross conveyor and selectively operable to apply a force in the first direction to selected articles exiting the infeed conveyor to push the selected articles across a width of the roller-top conveyor belt to the first destination; the booster comprises an electrically assisted roller that is selectively rotated in the first direction to push articles destined for the first destination over the article support belt rollers on the cross conveyor to the first destination; a speed of the electrically assisted roller is adjusted to be less than a speed of the infeed conveyor to slow down articles destined for the second or third destination being fed onto the roller-top conveyor belt.

2. 2. The sorting system of claim 1, wherein the first, second, and third destinations are conveyor belts that transport articles from the cross conveyor.

3. 2. The sorting system of claim 1, wherein the speed of the power-assisted rollers is great enough to ensure that the inertia of the articles destined for the first destination is sufficient to move the articles over the roller-top conveyor belt to the first destination.

4. 2. The sorting system of claim 1, wherein the in-feed conveyor has an in-feed drive that drives the in-feed conveyor, the in-feed drive being coupled to the power-assisted rollers to drive the power-assisted rollers.

5. 10. The sorting system of claim 1, comprising a drive unit and a clutch that selectively engages and disengages the drive unit from the power-assisted rollers.

6. A sorting system, comprising: an infeed conveyor that advances the articles in a first direction from an inlet to an outlet; A cross conveyor, a first side and an opposite second side spaced apart in the first direction; 1. A roller-top conveyor belt having a first end and an opposite second end, a roller-top conveyor belt arranged to selectively move in a second direction perpendicular to the first direction or in a third direction opposite the second direction; a cross conveyor including a plurality of article supporting belt rollers freely rotatable in the first direction; a first destination positioned on the second side of the roller-top conveyor belt opposite the in-feed conveyor for receiving articles passing over the article support belt rollers across the roller-top conveyor belt in the first direction; a second destination at the first end of the roller-top conveyor belt for receiving articles discharged from the first end of the roller-top conveyor belt advancing in the second direction; a third destination at the second end of the roller-top conveyor belt for receiving articles discharged from the second end of the roller-top conveyor belt advancing in the third direction; and a booster disposed between the outlet of the infeed conveyor and the first side of the cross conveyor and selectively operable to apply a force in the first direction to selected articles exiting the infeed conveyor to push the selected articles across a width of the roller-top conveyor belt to the first destination; the booster has an outlet positioned at the outlet end of the infeed conveyor to direct an air jet at articles intended for the first destination, and the sorting system includes an air manifold that pushes the selected articles past the article support belt rollers on the cross conveyor to the first destination.

7. 2. The sorting system of claim 1, wherein the force applied by the booster in the first direction imparts an inertia force to the articles intended for the first destination that is sufficient to cause the articles to cross the roller-top conveyor belt and reach the first destination.

8. 2. The sorting system of claim 1, wherein the roller-top conveyor belt stops when an article intended for the first destination passes over the roller-top conveyor belt.

9. 10. The sorting system of claim 1, wherein the booster does not apply a force in the first direction to items intended for the second or third destinations.

10. 1. A sorting system comprising: a main conveyor line including a series of main conveyor segments that advance articles in a first direction from an inlet to an outlet of each main conveyor segment; a plurality of cross conveyors intersecting the main conveyor line between the main conveyor segments, each of the cross conveyors comprising: a first side and an opposite second side spaced apart in the first direction; 1. A roller-top conveyor belt having a first end and an opposite second end, a roller-top conveyor belt arranged to selectively move in a second direction perpendicular to the first direction or in a third direction opposite the second direction; a plurality of cross conveyors, each including a plurality of article-supporting belt rollers freely rotatable in the first direction; a first destination at the first end of the roller-top conveyor belt for receiving articles discharged from the first end of the roller-top conveyor belt advancing in the second direction; a second destination at the second end of the roller-top conveyor belt for receiving articles discharged from the second end of the roller-top conveyor belt advancing in the third direction; and a booster disposed between the exit of each main conveyor segment and the first side of each cross conveyor that intersects the main conveyor line, the booster selectively operable to apply a force in a first direction to selected articles exiting each main conveyor segment to urge the selected articles across a width of the roller-top conveyor belt to the entrance of a next main conveyor segment in the main conveyor line; the booster comprises an electrically assisted roller selectively rotated in the first direction to push articles past the article support belt rollers on the cross conveyor; A sorting system wherein the speed of the power-assisted roller is adjusted to be less than the speed of an adjacent main conveyor segment to slow down articles destined for the first or second destination on the adjacent cross conveyor.

11. 11. The sorting system of claim 10, wherein the first and second destinations and the main conveyor segment are conveyor belts that transport articles from the cross conveyor.

12. 11. The sorting system of claim 10, wherein the speed of the power-assisted rollers is great enough to ensure that the inertia of items destined to continue along the main conveyor line is sufficient to overcome the roller-top conveyor belt.

13. A sorting system, comprising: a main conveyor line including a series of main conveyor segments that advance articles in a first direction from an inlet to an outlet of each main conveyor segment; a plurality of cross conveyors intersecting the main conveyor line between the main conveyor segments, each of the cross conveyors comprising: a first side and an opposite second side spaced apart in the first direction; 1. A roller-top conveyor belt having a first end and an opposite second end, a roller-top conveyor belt arranged to selectively move in a second direction perpendicular to the first direction or in a third direction opposite the second direction; a plurality of cross conveyors, each including a plurality of article-supporting belt rollers freely rotatable in the first direction; a first destination at the first end of the roller-top conveyor belt for receiving articles discharged from the first end of the roller-top conveyor belt advancing in the second direction; a second destination at the second end of the roller-top conveyor belt for receiving articles discharged from the second end of the roller-top conveyor belt advancing in the third direction; and a booster disposed between the exit of each main conveyor segment and the first side of each cross conveyor that intersects the main conveyor line, the booster selectively operable to apply a force in a first direction to selected articles exiting each main conveyor segment to urge the selected articles across a width of the roller-top conveyor belt to the entrance of a next main conveyor segment in the main conveyor line; the booster has an outlet positioned at the exit end of the main conveyor segment to direct an air jet at articles destined to continue along the main conveyor line, and the sorting system includes an air manifold for pushing the selected articles past the article support belt rollers on the cross conveyor.

14. 11. The sorting system of claim 10, wherein the force applied by the booster in the first direction imparts an inertia force to the article intended to continue along the main conveyor line sufficient to cause the article to clear the roller-top conveyor belt.

15. 11. The sorting system of claim 10, wherein the roller-top conveyor belt stops when an article destined to continue along the main conveyor line passes over the roller-top conveyor belt.

16. 11. The sorting system of claim 10, wherein the booster does not apply a force in the first direction to articles intended for the first or second destination.

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