Modular roller conveyor

Abstract

A modular roller conveyor comprising a plurality of conveyor modules interconnected by a plurality of links. Each conveyor module comprises an inlet end and an outlet end, opposing side rails, and a conveying surface coupled to the opposing side rails. The links are operable to rotate the conveyor modules between a stacked configuration and a coplanar configuration. In an alternative embodiment, the modular roller conveyors may be pivotally connected by hinges disposed along a periphery of the bottom conveyor module. Each conveyor module may include separators at its inlet and outlet ends and wheels at the bottom conveyor module. Also disclosed is a system including a stacking tool operable to transition the modular roller conveyors between a stacked configuration and a coplanar configuration.

Description

Technical Field

[0001] The present invention generally relates to conveyors. More specifically, the present invention relates to a multi-purpose conveyor having individual conveyor modules that can be reconfigured to assist in the transportation or storage of articles.

Background Art

[0002] Conveyors are commonly used to transport articles from one location to another. Subsequently, the articles are typically manually packed and sorted onto individual pallets for further storage or transportation. In many cases, the use of a forklift or other machinery is required to transport the pallets within a warehouse or load the pallets onto an existing truck for transportation. These pallets are typically made of wood or other materials that are prone to wear.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The additional labor, machinery, and steps required to move products from the conveyor to the pallets and then move the individual pallets are costly and increase the likelihood that products will be damaged or overlooked during the process. Therefore, there is a need for a device that automates the loading and unloading of products, eliminates the steps of pallet loading and unloading, improves product throughput, and enhances the efficiency of transporting and storing individual articles.

Means for Solving the Problems

[0004] The present invention includes a modular roller conveyor comprising a plurality of conveyor modules interconnected by a plurality of links. Each conveyor module includes an inlet end, an outlet end, opposing side rails, and a conveying surface coupled to the opposing side rails. The links are operable to rotate the conveyor modules between a stacked configuration and a coplanar configuration.

[0005] In another embodiment, a plurality of individual modular roller conveyors or towers are pivotally connected by hinges positioned around the conveyor modules at the base of each tower.

[0006] In yet another embodiment, a modular roller conveyor system is provided. In this embodiment, each individual conveyor module of any of the above embodiments further comprises a pusher roller rotatably mounted between opposing side rails and positioned at the entrance end of the conveyor module. The system comprises a stacking tool detachably mounted to the modular roller conveyor and operable to rearrange the conveyor modules between a stacked configuration and a coplanar configuration. The stacking tool comprises a support base with an elevated platform, a main actuator, a bottom actuator, and a lift plate with an upper segment and a bottom segment, all interconnected using a plurality of hinges. The lift plate is operable to slidably engage with the pusher roller of each conveyor module, and the actuators are operable to rotate the modular roller conveyor between a stacked configuration and a coplanar configuration.

[0007] In any of the embodiments described above, each conveyor module may further comprise a pair of separators rotatably mounted at the inlet and outlet ends of each module, which are operable to change between an open and a closed position. Similarly, in any of the embodiments described above, wheels may be coupled to the bottom surface of the bottom conveyor module. [Brief explanation of the drawing]

[0008] The aforementioned and other objects, features, and advantages of the present invention will become apparent from the following detailed description, in conjunction with the accompanying drawings, which are given the same reference numerals for similar parts.

[0009] [Figure 1] Figure 1 shows a side perspective view of a modular roller conveyor with a coplanar configuration. [Figure 2] Figure 2 shows a side perspective view of a modular roller conveyor with a partially raised configuration. [Figure 3] Figure 3 shows a side perspective view of a modular roller conveyor with a stacked configuration. [Figure 4] Figure 4 shows a perspective view of a conveyor module with a separator in an open configuration. [Figure 5] Figure 5 shows a perspective view of a conveyor module with a separator in a closed configuration. [Figure 6] Figure 6 shows a focused perspective view of a separator in a closed configuration. [Figure 7] Figure 7 shows a cross-sectional view of a conveyor module with a separator in a closed configuration. [Figure 8] Figure 8 shows a cross-sectional view of a conveyor module with a separator in an open configuration. [Figure 9] Figure 9 shows a top perspective view of the bottom conveyor module. [Figure 10] Figure 10 shows a bottom perspective view of the bottom conveyor module. [Figure 11] Figure 11 shows a side perspective view of a plurality of modular roller conveyors according to an exemplary embodiment of the present invention. [Figure 12] Figure 12 shows an alternative configuration of the modular roller conveyor shown in Figure 11. [Figure 13] Figure 13 shows an alternative configuration of the modular roller conveyor shown in Figure 12. [Figure 14] Figure 14 shows multiple modular roller conveyors with a coplanar configuration used in product supply systems known in the art. [Figure 15] Figure 15 shows a side view of a modular roller conveyor system in which modular roller conveyors are stacked. [Figure 16] Figure 16 shows a focused perspective top view of the bottom segment of the lift plate of a modular roller conveyor system. [Figure 17]FIG. 17 shows a side view of a modular roller conveyor system having a modular roller conveyor with a partially raised configuration. [Figure 18] FIG. 18 shows a side view of a modular roller conveyor system in which the modular roller conveyors are in a coplanar configuration. [Figure 19] FIG. 19 shows a rear perspective view of a scaled modular roller conveyor system excluding the modular roller conveyor. [Figure 20] FIG. 20 shows a front perspective view of a scaled modular roller conveyor system excluding the modular roller conveyor. [Figure 21] FIG. 21 shows a front perspective view of a scaled modular roller conveyor system together with the corresponding modular roller conveyor.

[0010] The representations in the drawings are simplified for explanation purposes and are not drawn to a fixed scale. In the description of the drawings, similar elements are provided with the same names and reference numerals as in the previous figure(s). The specific numbers assigned to the elements are provided only to assist in the description and are not intended to imply any (structural or functional) limitations on the present invention.

[0011] The accompanying drawings show exemplary configurations of the present invention and should not be regarded as limiting the scope of the present invention in themselves. Without further explanation, it is conceivable that the features of one configuration can be beneficially incorporated into other configurations.

BEST MODE FOR CARRYING OUT THE INVENTION

[0012] To further understand the nature and functions of the embodiments, reference should be made to the following detailed description. As used herein, "axis" means an actual or virtual straight line about which a three-dimensional object is symmetric.

[0013] Referring to FIGS. 1-3, another perspective view of the modular roller conveyor 5 of various configurations is shown. The modular roller conveyor 5 includes a plurality of conveyor modules 10 that are operable to transition from a coplanar configuration to a stacked configuration. FIG. 1 shows the modular roller conveyor 5 in a coplanar configuration where each individual conveyor module 10 is sequentially aligned in a single plane along axis A-A. FIG. 2 shows the modular roller conveyor 5 in a partially raised configuration, and FIG. 3 shows the modular roller conveyor 5 in a stacked configuration where one conveyor module is disposed at the bottom and each individual conveyor module 10 is disposed along the vertical axis B-B above the bottom conveyor module 130 (as shown in detail in FIGS. 9-10).

[0014] The individual conveyor modules 10 are connected to each other by a plurality of links 15 in a manner similar to a planar four-bar link system in which each conveyor module 10 functions as one of four links. In the illustrated exemplary embodiment, each conveyor module 10 has a plurality of attachment points 20 disposed along the outer surface 25 on the opposing side rails 30. The links 15 are rotatably connected at these attachment points 20 using fasteners such that the links 15 can rotate freely about the fasteners and axially with respect to the conveyor module 10. In the case of the modular roller conveyor 5 having two conveyor modules 10, two links 15 are required on both sides of the modular roller conveyor 5. For each additional conveyor module 10, an additional link 15 is required on both sides of the modular roller conveyor 5.

[0015] Figures 4 to 8 show exemplary embodiments of individual conveyor modules 10 contained within a modular roller conveyor 5. Each conveyor module 10 has an inlet end 40 and an outlet end 50, and comprises opposing side rails 30 and a conveying surface 60 coupled to the side rails and operable to transport articles from the inlet end 40 to the outlet end 50. As shown in the figures, the conveying surface 60 may comprise one or more rollers rotatably mounted between the opposing side rails 30, which may be power rollers or may be driven manually, by gravity, or externally by a separate power source such as a motor. Furthermore, it is anticipated that other conveying means, including flat belt conveyors, magnetic belt conveyors, or wheel conveyors, may be used instead of rollers.

[0016] In an alternative embodiment, each conveyor module 10 is equipped with separators 70 at the inlet end 40 and outlet end 50 of each individual conveyor module 10. Figure 4 shows these separators 70 in an open position where products can flow freely on the conveying surface 60. Figure 5 shows these separators 70 in a closed configuration where products are confined to the area between the separators 70. These separators 70 allow a user to load a specific amount of product or food onto each individual conveyor module 10. In an exemplary embodiment, the separators 70 are spring-loaded in the closed configuration. Each separator is sized and dimensional so as to be able to move freely up and down without obstructing the conveying surface 60, and the end 80 of each separator 70 is sized and dimensional so as to fit into a slot 90 located on the inner surface 100 of the side rail 30. Each separator 70 further comprises a strip of magnetic material 110 (e.g., iron) that extends beneath the conveyor module 10 and is positioned in close proximity to a solenoid 120 mounted on a conveyor support frame beneath the conveyor module 10 (as shown in Figures 7-8). The solenoids 120 are operable to actuate each separator 70 such that the magnetic field generated by each solenoid 120 pulls the separator 70 down from a closed position to an open position. The conveyor module 10 is expected to include other sensors that communicate with a control module operable to regulate the current supplied to each solenoid 120, and can be configured to open and close the separators 70 when a certain amount of food or product passes over them.

[0017] Referring to Figures 9 and 10, an exemplary embodiment of a conveyor module 130 located at the bottom of a modular roller conveyor 5 is shown. The bottom conveyor module 130 comprises a number of hinges 140 arranged along its perimeter. These hinges 140 can be fixedly attached to the conveyor module 10 by molding, welding, or some other mounting means, or they can be detachably attached using fasteners (e.g., snap-fits). In the figures, these hinges 140 are located at each of the four corners of the bottom conveyor module 130 where the side rails 30 intersect with the entrance end 40 and the exit end 50. In alternative embodiments, the number of these hinges 140 may be fewer and located elsewhere along the perimeter of the conveyor module 10. As shown in Figure 10, wheels 150 may be attached to the bottom surface 155 of the bottom conveyor module 130, thereby making it movable when the modular roller conveyor 5 is in a stacked configuration.

[0018] Referring to Figures 11-13, the various configurations of the separate modular roller conveyors 5 are interconnected by hinges 140 arranged around the bottom conveyor module 130. For the purposes of this application, the individual modular roller conveyors 5 in a stacked configuration are also referred to as "towers." As shown, the hinges 140 allow each individual tower 5 to be operated into a more compact unit for storage or transport purposes.

[0019] In practice, embodiments of the present invention enable the efficient palletization of products using individual modular roller conveyors 5. As shown in Figure 14, multiple gravity-feed modular roller conveyors 5, arranged at an angle, are connected to a product supply system that allows products or articles to be manually fed onto each individual roller conveyor module 10. After the articles are loaded onto the individual conveyor modules 10, the individual towers 5 return to a stackable configuration, allowing the towers 5 to be repositioned or moved to a different location according to user needs.

[0020] Referring to Figures 15–18, an exemplary modular roller conveyor system 160 is shown that is operable to transition the modular roller conveyor 5 between its coplanar and stacked configurations. A key aspect of this system is its ability to stabilize the bottom roller conveyor module 130 when the modular roller conveyor 5 transitions between configurations and to provide means for the modular roller conveyor 5 to be at a suitable height for the user during the coplanar configuration. To do this, a preferred embodiment of the modular roller conveyor system 160 comprises a stacking tool 165 which includes a support base 170 having a raised platform 180 and support means which may include one or more support legs 190. The stacking tool 165 further comprises a lift plate 220 having a main actuator 200, a bottom actuator 210, and an upper segment 230 and a bottom segment 240, which are interconnected using a plurality of hinges 205 or other fasteners that allow movement of the lift plate 220 and rotate around a pivot axis fixed to the support base 170. The main actuator 200 and the bottom actuator 210 can be actuated by pneumatic, electric, or hydraulic means. As detailed in Figure 16, to prevent the bottom roller conveyor module 130 from rotating during transition, a chock 250 that can be operated to prevent rotation is positioned where the upper segment 230 meets the bottom segment 240 of the lift plate 220. Also, as shown in Figures 4 to 6, each conveyor module 10 has a separate pusher roller 270 that is rotatably mounted between opposing side rails 30 and positioned at each inlet end 40 of the conveyor module 10. The lift plate 220 engages with the pusher rollers 270 of each conveyor module 10 in a similar manner to cams and driven mechanisms. The pusher rollers 270 provide a friction-reducing element that allows the conveyor module 10 to lift up while transitioning between configurations.

[0021] When the main actuator 200 extends and the bottom actuator 210 retracts, the lift plate 220 slidably engages with the individual pusher rollers 270 of each conveyor module 10, and operates to push the modular roller conveyor 5 into a stacked position. Conversely, when the main actuator 200 retracts and the bottom actuator 210 extends, the lift plate 220 operates to rearrange the modular roller conveyor 5 into a coplanar configuration.

[0022] As shown in Figure 16, when the separator 70 is used in the conveyor module 10, the lift plate 220 further includes an opening 260 that is operable to receive the magnetic strip 110 when transitioning to a coplanar configuration.

[0023] Referring to Figures 19 to 21, an exemplary embodiment of a scaled-up version of a modular roller conveyor system 160 capable of supporting multiple modular roller conveyors 5 is shown. As illustrated, the modular roller conveyor system 160 can be modified and scaled to support a larger number of modular roller conveyors 5 to meet user needs.

[0024] For the purpose of facilitating an understanding of the principles of the present invention, embodiments shown in the drawings have been referenced, and specific terminology has been used to describe these embodiments. However, this specific terminology is not intended to limit the scope of the present invention, and it should be interpreted that the present invention encompasses all embodiments that a person skilled in the art would ordinarily conceive. The implementations shown and described herein are illustrative examples of the present invention and are not intended to limit the scope of the present invention in any way. For the sake of brevity, conventional aspects of the method (and components of the individual operating components of the method) may not be described in detail. Furthermore, the connecting lines or connectors shown in the various figures presented are intended to represent exemplary functional relationships and / or physical or logical connections between various elements. It should be noted that many alternative or additional functional relationships, physical connections, or logical connections may exist in actual devices. Furthermore, no article or component is essential to the implementation of the present invention unless it is specifically stated that that element is “essential” or “important.” Many modifications and adaptations will be readily apparent to a person skilled in the art without departing from the spirit and scope of the present invention.

Claims

1. A modular roller conveyor comprising multiple conveyor modules connected by multiple links, wherein each conveyor module is Entrance end and exit end, Opposing side rails, A transport surface connected to the side rail and capable of operating to transport articles from the entrance end to the exit end, Equipped with, The link is rotatably connected to the side rail of the conveyor module and is operable to move the conveyor module between a stacked configuration and a coplanar configuration. In the aforementioned stacking configuration, one of the conveyor modules is positioned at the bottom, and each additional conveyor module is positioned above the bottom conveyor module along a vertical axis, with each conveying surface of each conveyor module facing upward. In the aforementioned coplanar configuration, the conveying surfaces of each conveyor module are facing upward and are sequentially aligned and continuous along a single plane, forming a modular roller conveyor.

2. The modular roller conveyor according to claim 1, wherein the conveying surface is selected from the group including gravity rollers, power rollers, flat belt conveyors, magnetic belt conveyors, and wheel conveyors.

3. The modular roller conveyor according to claim 1, wherein separators are provided at the inlet end and the outlet end of the conveyor module, and each separator is operable to be in a first open position or a second closed position.

4. A modular roller conveyor according to claim 1, comprising a plurality of wheels connected to the bottom surface of a bottom conveyor module.

5. It is a modular roller conveyor, Multiple modular roller conveyors, each modular roller conveyor comprising multiple conveyor modules connected by multiple links, each conveyor module is At the entrance edge, The exit end and Opposing side rails, A transport surface connected to the side rail and capable of operating to transport articles from the entrance end to the exit end, Equipped with, The link is rotatably connected to the side rail of the conveyor module and is operable to rotate the conveyor module between a stacked configuration and a coplanar configuration. In the stacked configuration described above, one of the conveyor modules is located at the bottom, and each additional conveyor module is positioned above the bottom conveyor module along a vertical axis. In the aforementioned coplanar configuration, each of the conveying surfaces of the conveyor modules is sequentially aligned and continuous along a single plane, comprising a plurality of modular roller conveyors, Multiple hinges are arranged around the bottom conveyor module, Equipped with, The aforementioned multiple modular roller conveyors are connected pivotally by the hinges, forming a modular roller conveyor.

6. The modular roller conveyor according to claim 5, wherein the conveying surface is selected from the group including gravity rollers, power rollers, flat belt conveyors, magnetic belt conveyors, and wheel conveyors.

7. The modular roller conveyor according to claim 5, wherein separators are provided at the inlet end and the outlet end of the conveyor module, and each separator is operable to be in a first open position or a second closed position.

8. The modular roller conveyor according to claim 5, further comprising a plurality of wheels connected to the bottom surface of the bottom conveyor module.

9. A modular roller conveyor system, A modular roller conveyor comprising multiple conveyor modules connected by multiple links, wherein each conveyor module is Entrance end and exit end, Opposing side rails, A transport surface connected to the side rail and capable of operating to transport articles from the entrance end to the exit end, A pusher roller is rotatably mounted between the opposing side rails and positioned at the entrance end of each of the conveyor modules, Equipped with, The link is rotatably connected to the side rail of the conveyor module and is operable to move the conveyor module between a stacked configuration and a coplanar configuration. In the aforementioned stacking configuration, one of the conveyor modules is positioned at the bottom, and each additional conveyor module is positioned above the bottom conveyor module along a vertical axis, with each conveying surface of each conveyor module facing upward. In the aforementioned coplane configuration, the conveying surfaces of each conveyor module are upward-facing and sequentially aligned and continuous along a single plane, forming a modular roller conveyor. A stacking tool that is detachably attached to the modular roller conveyor and is operable to rearrange the conveyor modules between the stacking configuration and the coplanar configuration, A modular roller conveyor system equipped with [the following features].

10. The stacking tool comprises a support base with an elevated platform, a main actuator, a bottom actuator, and a lift plate with an upper segment and a bottom segment. The base, the main actuator, the bottom actuator, and the lift are interconnected using a plurality of hinges. The lift plate is slidably engaged with the pusher roller of each conveyor module, The main actuator and the bottom actuator are capable of operating to rotate the modular roller conveyor between the stacked configuration and the coplanar configuration. The modular roller conveyor system according to claim 9, wherein when the main actuator extends and the bottom actuator retracts, the modular roller conveyor is arranged in the stacked configuration, and when the main actuator retracts and the bottom actuator extends, the modular roller conveyor is arranged in the coplanar configuration.

11. The modular roller conveyor system according to claim 9, wherein the conveying surface is selected from the group including gravity rollers, power rollers, flat belt conveyors, magnetic belt conveyors, and wheel conveyors.

12. The modular roller conveyor system according to claim 9, wherein separators are provided at the inlet end and the outlet end of the conveyor module, and each separator is operable to be in a first open position or a second closed position.

13. The modular roller conveyor system according to claim 9, further comprising a plurality of wheels connected to the bottom surface of the conveyor module at the bottom.

14. Equipped with multiple modular roller conveyors, The modular roller conveyor system according to claim 9, wherein the stacking tool is detachably attached to each modular roller conveyor and is operable to rearrange each conveyor module between the stacking configuration and the coplanar configuration.

15. A modular roller conveyor comprising at least three conveyor modules connected by multiple links, wherein each conveyor module is Entrance end and exit end, Opposing side rails, A transport surface connected to the side rail and capable of operating to transport articles from the entrance end to the exit end, Equipped with, The link is rotatably connected to the side rail of the conveyor module and is capable of moving the conveyor module between a stacked configuration and a co-plane configuration while maintaining the conveying surface of each conveyor module parallel to the conveying surface of the bottom conveyor module. In the stacked configuration described above, one of the conveyor modules is located at the bottom, and each additional conveyor module is positioned above the bottom conveyor module along a vertical axis. In the aforementioned coplanar configuration, the conveying surfaces of each conveyor module are sequentially aligned and continuous along a single plane, forming a modular roller conveyor.

16. Each of the conveyor modules between the bottom conveyor module and the top conveyor module has three mounting points on each side rail to which the link is rotatably attached: a first mounting point at the exit end, a second mounting point at the entrance end, and a third mounting point between the first and second mounting points. A modular roller conveyor according to claim 15, wherein one end of the link attached to the third mounting point of one of the conveyor modules is attached to the first mounting point of an adjacent conveyor module of the conveyor module, and the other end of the link is attached to the second mounting point of another adjacent conveyor module of the conveyor module.

17. The modular roller conveyor according to claim 15, wherein the conveying surface is selected from the group including gravity rollers, power rollers, flat belt conveyors, magnetic belt conveyors, and wheel conveyors.

18. The modular roller conveyor according to claim 15, wherein separators are provided at the inlet end and the outlet end of the conveyor module, and each separator is operable to be in a first open position or a second closed position.

19. The modular roller conveyor according to claim 15, further comprising a plurality of wheels connected to the bottom surface of the conveyor module at the bottom.

20. The modular roller conveyor according to claim 15, wherein each of the side rails has a height that extends by a distance above the conveying surface.

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