Alignment transfer systems and methods

Abstract

Methods, systems, assemblies, and / or the like are provided. According to various embodiments, there is provided a transfer alignment system including one or more feed belts, wherein the one or more feed belts are configured to transfer one or more wall boards in a first direction; one or more rollers, wherein the one or more rollers are configured to transfer one or more wall boards along a second direction, wherein the second direction is lateral to the first direction; and one or more pulley alignment assemblies comprising a core; and a belting lagged on a circumference of the core, wherein the one or more pulley alignment assemblies are configured to transfer the one or more wall boards onto a stacker table.

Description

ALIGNMENT TRANSFER SYSTEMS AND METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to and the benefit of U.S. Provisional Patent Application Serial No. 63 / 529,155, filed July 27, 2023; the contents of which as are hereby incorporated by reference herein in their entirety.TECHNICAL FIELD

[0002] The present disclosure generally relates to alignment transfer systems. In particular, it relates to alignment transfer systems for use in gypsum board manufacturing.BACKGROUND

[0003] During the manufacture of wall board (e.g., gypsum), the wall boards are transferred (e.g., via pulleys, rollers, pushers, and / or the like) onto various production tables (e.g., a stacker scissor table). As a result of this transfer, the wall board may undergo one or more stresses that may cause the wall board to separate (e.g., one or more of the board’s layers may separate from the others). For example, a separated piece of wall board may be transferred onto a production table only to have its top layer separate during transfer, resulting in damage to the product as well as potential jamming of the machinery.

[0004] Through applied effort, ingenuity, and innovation, Applicant has solved problems relating to wall board separation during manufacturing by developing solutions embodied in the present disclosure, which are described in detail below.SUMMARY

[0005] In general, embodiments of the present disclosure provide methods, systems, assemblies, and / or the like.

[0006] In accordance with various embodiments of the present disclosure there is provided a transfer alignment system including: one or more feed belts, wherein the one or more feed belts are configured to transfer one or more wall boards in a first direction; one or more rollers, wherein the one or more rollers are configured to transfer one or more wall boards along a second direction, wherein the second direction is lateral to the first direction; and one or more pulley alignmentassemblies including: a core; and a belting lagged on a circumference of the core, wherein the one or more pulley alignment assemblies are configured to transfer the one or more wall boards onto a stacker table.

[0007] In some embodiments, further including the stacker table.

[0008] In some embodiments, the transfer alignment system includes a stacker scissor table.

[0009] In some embodiments, the transfer alignment system includes one or more risers, wherein the one or more rollers are disposed on or within the one or more risers, and wherein the one or more risers are configured to elevate or lower the one or more rollers such that the one or more feed belts and the one or more rollers are disposed in separate planes.

[0010] In some embodiments, the transfer alignment system includes the one or more feed belts, which include one or more head shafts disposed at a first or second end of the one or more feed belts, and wherein the one or more pulley alignment assemblies are coupled to the one or more head shafts.

[0011] In some embodiments, the core includes a first half and a second half, and wherein the first half and the second half are fixedly attached by one or more fasteners.

[0012] In some embodiments, the transfer alignment system further includes one or more pushers configured to actuate in the first or the second direction to push the one or more wall boards onto the stacker table.

[0013] In some embodiments, the wall board is gypsum board having one or more material layers.

[0014] In some embodiments, the belting is diamond top belting.

[0015] In some embodiments, the one or more pulley alignment assemblies include two pulley alignment assemblies that are two inches wide, and wherein the two pulley alignment assemblies are spaced apart from each other by four feet in the second direction.

[0016] According to various embodiments, there is provided a method of using a transfer alignment system. In some embodiments, the method includes transferring in a first direction, by one or more feed belts, one or more wall boards; transferring in a second direction, by one or more rollers, the one or more wall boards, wherein the second direction is lateral to the first direction; aligning, by one or more alignment pulley alignment assemblies, the one or more wall boards; and depositing, by the one or more feed belts, the one or more wall boards onto a stacker table.

[0017] The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some embodiments of the disclosure. Accordingly, it will be appreciated that the above-described embodiments are merely examples. It will be appreciated that the scope of the disclosure encompasses many potential embodiments in addition to those here summarized, some of which will be further described below.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0018] Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0019] FIGS. 1A-1D show isometric views of an example transfer alignment system, in accordance with various embodiments of the present disclosure;

[0020] FIG. 2A shows an angled perspective view of an example pulley alignment assembly, in accordance with various embodiments of the present disclosure;

[0021] FIG. 2B shows an elevation side view of an example pulley alignment assembly, in accordance with various embodiments of the present disclosure;

[0022] FIG. 3 A shows a bottom plan view of an example pulley alignment assembly, in accordance with various embodiments of the present disclosure;

[0023] FIG. 3B shows a top plan view of an example pulley alignment assembly in accordance with various embodiments of the present disclosure; and

[0024] FIG. 4 is a flow chart illustrating an example method of using an example alignment pulley system, in accordance with various embodiments of the present disclosure.DETAILED DESCRIPTION OF SOME EXAMPLE EMBODIMENTS

[0025] Various embodiments of the present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Indeed, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The term “or” (also designated as “ / ”) is used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms “illustrative” and “exemplary” are used to be examples with no indication of quality level. Like numbers may refer to like elements throughout. The phrases “in oneembodiment,” “according to one embodiment,” and / or the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily may refer to the same embodiment).Overview

[0026] According to various embodiments, there is provided a transfer alignment system for manufacturing wall boards. In some embodiments, the transfer alignment system may be used to move one or more wall boards between various production sites during manufacturing. In some embodiments, the transfer alignment system may be utilized when the wall boards are stacked during manufacture. In some embodiments, the transfer and transfer alignment system may include one or more feed belts and one or more rollers configured to transfer the wall board from one production site to another. In some embodiments, the transfer alignment system may use one or more alignment pulley alignment assemblies. In some embodiments, the one or more alignment pulley alignment assemblies may be configured to prevent the board from separating as it is transferred from one production site to the next.Example Transfer alignment systems

[0027] FIGS. 1A-1D show isometric views of an example transfer alignment system 100 (“system 100”), according to various embodiments. In some embodiments, the system 100 may be configured to transfer and align one or more wall boards 102. In some embodiments, the one or more wall boards 102 may be rectangular-shaped boards having a length, width, and thickness. In some embodiments, the one or more wall boards may be gypsum boards having one or more material layers. In some embodiments, the system 100 may transfer the one or more wall boards 102 throughout a production site to one or more locations (e.g., a stacking location, such as a stacker scissor table).

[0028] In some embodiments, the system 100 may include one or more feed belts 104 and one or more rollers 106. The one or more feed belts 104 and the one or more rollers 106 may be configured to support the wall board at one or more steps in the manufacturing process. In some embodiments, the one or more feed belts 104 are configured to transfer the wall boards in a first direction and the one or more rollers 106 are configured to transfer the wall boards in a seconddirection, lateral to the first direction. In some embodiments, the first and second directions may be perpendicular. In some embodiments, the one or more feed belts 104 and the one or more rollers 106 may be disposed on separate planes such that they refrain from acting simultaneously on the wall boards.

[0029] In some embodiments, the system 100 may include one or more risers 108. In some embodiments, the one or more risers 108 may be a rectangular, box-shaped component with an open top. In some embodiments, the one or more risers 108 may be configured to raise or lower one or more components of the system 100, as desired. In some embodiments, one or more of the one or more rollers 106 may be disposed on or within the one or more risers 108, such that the one or more risers 108 may bring the one or more rollers 106 to a separate plane from the one in which the one or more feed belts 104 are disposed. For example, the one or more rollers 106 may be lifted above the feed belts. Once the one or more rollers 106 are in a separate plane from the feed belts 104, the one or more rollers 106 may transfer the wall boards 102 laterally to the feed belts 104 to a desired location, then the risers 108 may lower the rollers 106, allowing the feed belts 104 to transfer the wall boards 102 lateral to the rollers 106 to another desired location (e.g., a stacker table 110).

[0030] In some embodiments, the system 100 may include a stacker table 110. In some embodiments, the stacker table 110 may be a stacker scissor table. In some embodiments, the stacker table 110 may be a rigid table structure configured to support the one or more wall boards 102. In some embodiments, the system 100 may be configured to transfer the one or more wall boards 102 to the stacker table 110 for stacking. Once the one or more wall boards 102 have been stacked, they can be moved to another part of the production / manufacturing process.

[0031] In some embodiments, the system 100 may include one or more pushers 112. In some embodiments, the one or more pushers 112 may be configured to “push” the one or more wall boards 102 onto the stacker table 110. The one or more pushers 112 may be actuators configured to move in a direction toward the center of the stacker table 110. In some embodiments, the one or more pushers 112 may align the one or more wall boards 102 once they are stacked on top of each other. In some embodiments, the one or more pushers 112 may be disposed around the stacker table 110 and actuate in unison such that the wall board 102 is acted on with equal force from two or more sides, such that the wall board 102 is “pushed” toward the center of the stacker table 110 and aligned with other wall boards 102 in the stack.

[0032] In some embodiments, the system 100 may include one or more alignment pulley alignment assemblies 114A, 114B. The alignment pulley alignment assemblies 114A, 114B may be disposed proximate to one or more ends of the one of more feed belts 104. In some embodiments, the one or more alignment pulley alignment assemblies 114A, 114B may be two- inches wide. In some embodiments, a pair of alignment pulley alignment assemblies 114A, 114B may be disposed proximate to the ends of the one or more feed belts 104 on the system 100; in some embodiments, the pair of pulley alignment assemblies 114A, 114B may be separated by a width of the one or more wall boards 102.

[0033] FIG. 2A shows an angled perspective view of an example pulley alignment assembly 114A (referred to as 114A for simplicity only; it will be understood the description of pulley alignment assembly 114A may be applied to pulley alignment assembly 114B), and FIG. 2B shows an elevation side view of the example pulley alignment assembly 114A, in accordance with various embodiments of the present disclosure. FIG. 3 A shows a bottom plan view of an example pulley alignment assembly 114A, and FIG. 3B shows a top plan view of the example pulley alignment assembly 114 A, in accordance with various embodiments of the present disclosure.

[0034] In some embodiments, the pulley alignment assembly 114A may include a core 116. In some embodiments, the core 116 may be a rigid, metallic, substantially annular plate. In some embodiments, the core 116 may have a substantially circular shape with curved edges. In some embodiments, the core 116 may include one or more curved edges and one or more flat, planar edges. In some embodiments, the core 116 may include a central hole 118.

[0035] In some embodiments, and as shown in at least FIGS. 3 A and 3B, the core 116 may include a first half 120A and a second half 120B. In some embodiments, the first and second halves 120 A, 120B may be operably attached by one or more fasteners 119A, 119B to thereby form the core 116. In some embodiments the first and second halves 120A, 120B may be substantially halfmoon shaped components that, when connected together, define the central hole 118. In some embodiments, the first and second halves 120 A, 120B may define one or more slots 122A-D. As shown in FIG. 3B, in some embodiments, the one or more slots 122A-D may not go all the way through either the first and / or second halves 120A-B. In some embodiments, the one or more fasteners 119A, 119B may include bolts, nuts, and / or washers, as shown in the various figures. It will be understood that the fasteners 119A, 119B may include various other fastening devices (e. g. , pins, screws, and / or the like).

[0036] In some embodiments, the pulley alignment assembly 114A may include a belting 124. In some embodiments, the belting 124 may be disposed along an outer edge of the core 116A. In some embodiments, the pulley alignment assembly 114A may support and / or operably engage with the one or more wall boards 102 and assist in transferring the one or more wall boards 102 onto the stacker table 110. The belting 124 may contact with and / or operably engage with the one or more wall boards 102 when the one or more wall boards are transferred onto the stacker table 110. The pulley alignment assembly 114A and / or the belting 124 may be configured to keep the one or more wall boards 102 from misaligning on the stacker table, or “lagging” behind the stacking of other wall boards 102. In some embodiments, the belting 124 may define a circumference of the pulley alignment assembly 114A. In some embodiments, the belting 124 may be a diamond-top belting that is lagged on both the first half 120 A and the second half 120B of the pulley alignment assembly 114A. In some embodiments, and as shown in at least FIG. 2B, the belting 124 may be secured to the core 116 via one or more brackets 126 A, 126B, which may be secured to the core 116 via one or more belting fasteners 128A-128D.Example Methods of Use

[0037] FIG. 4 is a flow chart illustrating an example method 200 of using an example transfer alignment system, in accordance with various embodiments of the present disclosure. FIG. 4 is described with reference to the system 100 and its various components and assemblies as previously described. It will be understood that the method 200 may be implemented using other suitable systems, components, assemblies, and / or the like, as desired.

[0038] In some embodiments, the method 200 may include a step 202, of transferring in a first direction, by one or more feed belts, one or more wall boards.

[0039] In some embodiments, the method 200 may include a step 204 of transferring in a second direction, by one or more rollers, the one or more wall boards. In some embodiments, the second direction is lateral to the first direction. In some embodiments, the second direction may be perpendicular to the first direction.

[0040] In some embodiments, the method 200 may include a step 206 of aligning, by one or more alignment pulley alignment assemblies, the one or more wall boards.

[0041] In some embodiments, the method 200 may include a step 208 of depositing, by the one or more feed belts, the one or more wall boards onto a stacker table.

[0042] Many modifications and other embodiments of the disclosure set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

CLAIMS1. A transfer alignment system comprising: one or more feed belts configured to transfer one or more wall boards in a first direction; one or more rollers configured to transfer one or more wall boards along a second direction that is lateral to the first direction; and one or more pulley alignment assemblies comprising: a core; and a belting lagged on a circumference of the core, wherein the one or more pulley alignment assemblies are configured to transfer the one or more wall boards onto a stacker table.

2. The transfer alignment system of claim 1 , further comprising the stacker table.

3. The transfer alignment system of claim 2, wherein the stacker table comprises a stacker scissor table.

4. The transfer alignment system of claim 1 , further comprising one or more risers, wherein the one or more rollers are disposed on or within the one or more risers, and wherein the one or more risers are configured to elevate or lower the one or more rollers such that the one or more feed belts and the one or more rollers are disposed in separate planes.

5. The transfer alignment system of claim 1, wherein the one or more feed belts comprise one or more head shafts disposed at a first or second end of the one or more feed belts, and wherein the one or more pulley alignment assemblies are coupled to the one or more head shafts.

6. The transfer alignment system of claim 1 , wherein the core comprises a first half and a second half, and wherein the first half and the second half are fixedly attached by one or more fasteners.

7. The transfer alignment system of claim 1 further comprising one or more pushers configured to actuate in the first or the second direction to push the one or more wall boards onto the stacker table.

8. The transfer alignment system of claim 1, wherein the wall board comprises gypsum board comprising one or more material layers.

9. The transfer alignment system of claim 1 , wherein the belting comprises diamond top belting.

10. The transfer alignment system of claim 1 , wherein the one or more pulley alignment assemblies comprise two pulley alignment assemblies that are two inches wide, and wherein the two pulley alignment assemblies are spaced apart from each other by four feet in the second direction.

11. A method of using a transfer alignment system, the method comprising: transferring, via one or more feed belts, one or more wall boards in a first direction; transferring, via one or more rollers, the one or more wall boards in a second direction that is lateral to the first direction; aligning, via one or more alignment pulley alignment assemblies, the one or more wall boards; and depositing, via the one or more feed belts, the one or more wall boards onto a stacker table.

12. The method of claim 11, wherein the stacker table comprises a stacker scissor table.

13. The method of claim 11, wherein: the one or more rollers are disposed on or within one or more risers, and the method further comprises the step of elevating or lowering the one or more rollers such that the one or more feed belts and the one or more rollers are disposed in separate planes.

14. The method of claim 11, wherein: the one or more feed belts comprise one or more head shafts disposed at a first or second end of the one or more feed belts, and the method further comprises coupling the one or more pulley alignment assemblies to the one or more head shafts.

15. The method of claim 11, wherein: the core comprises a first half and a second half, and the method further comprises fixedly attaching the first half and the second half by one or more fasteners.

16. The method of claim 11, further comprising actuating one or more pushers in the first or the second direction to push the one or more wall boards onto the stacker table.

17. The method of claim 11, wherein the wall board comprises gypsum board comprising one or more material layers.

18. The method of claim 11, wherein the belting comprises diamond top belting.

19. The method of claim 11 , wherein the one or more pulley alignment assemblies comprise two pulley alignment assemblies that are two inches wide, and wherein the two pulley alignment assemblies are spaced apart from each other by four feet in the second direction.

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